Aerosol delivery device with improved connectivity, airflow, and aerosol paths

ABSTRACT

The present disclosure provides an aerosol delivery device and a cartridge for an aerosol delivery device. In various implementations, the aerosol delivery device comprises a control device that includes an outer housing defining a cartridge receiving chamber, and further includes a power source and a control component, and a cartridge that includes a mouthpiece, a tank, a heating assembly, and a bottom cap. The mouthpiece defines an exit portal in an end thereof, and the tank is configured to contain a liquid composition therein. The cartridge is configured to be removably coupled with the receiving chamber of the control device, and the heating assembly defines a vaporization chamber and is configured to heat the liquid composition to generate an aerosol. An inlet airflow is defined by a gap between the cartridge and the control device that originates at an interface between an outer peripheral surface the mouthpiece and control device.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Pat. Application No.16/598,496, titled Aerosol Delivery Device with Improved Connectivity,Airflow, And Aerosol Paths, filed on Oct. 10, 2019, which claimspriority to, and the benefit of, U.S. Provisional Pat. Application No.62/744,978, titled Aerosol Forming Device, filed on Oct. 12, 2018, andU.S. Provisional Pat. Application No. 62/911,519, titled AerosolDelivery Device with Improved Connectivity, Airflow, and Aerosol Paths,filed on Oct. 7, 2019, each of which is incorporated herein in itsentirety by reference.

TECHNOLOGY FIELD

The present disclosure relates to aerosol delivery devices such assmoking articles, and more particularly to aerosol delivery devices thatmay utilize electrically generated heat for the production of aerosol(e.g., smoking articles commonly referred to as electronic cigarettes).The smoking articles may be configured to heat an aerosol precursor,which may incorporate materials that may be made or derived from tobaccoor otherwise incorporate tobacco, the precursor being capable of formingan inhalable substance for human consumption.

BACKGROUND

Many smoking devices have been proposed through the years asimprovements upon, or alternatives to, smoking products that requirecombusting tobacco for use. Many of those devices purportedly have beendesigned to provide the sensations associated with cigarette, cigar, orpipe smoking, but without delivering considerable quantities ofincomplete combustion and pyrolysis products that result from theburning of tobacco. To this end, there have been proposed numeroussmoking products, flavor generators, and medicinal inhalers that utilizeelectrical energy to vaporize or heat a volatile material, or attempt toprovide the sensations of cigarette, cigar, or pipe smoking withoutburning tobacco to a significant degree. See, for example, the variousalternative smoking articles, aerosol delivery devices, and heatgenerating sources set forth in the background art described in U.S.Pat. No. 7,726,320 to Robinson et al., U.S. Pat. App. Pub. No.2013/0255702 to Griffith Jr. et al., and U.S. Pat. App. Pub. No.2014/0096781 to Sears et al., which are incorporated herein by referencein their entireties. See also, for example, the various types of smokingarticles, aerosol delivery devices, and electrically powered heatgenerating sources referenced by brand name and commercial source inU.S. Pat. App. Ser. No. 14/170,838 to Bless et al., filed Feb. 3, 2014,which is incorporated herein by reference in its entirety. It would bedesirable to provide an aerosol delivery device with advantageoususability features.

BRIEF SUMMARY

The present disclosure relates to aerosol delivery devices, methods offorming such devices, and elements of such devices. The disclosureparticularly relates to an aerosol delivery device and a cartridge foruse in an aerosol delivery device. In this regard, various embodimentsof the disclosure provide an aerosol delivery device and/or a cartridgewith advantageous usability features. The present disclosure includes,without limitation, the following example implementations:

An aerosol delivery device comprising a control device that includes anouter housing defining an outer wall and having a proximal end and adistal end, the proximal end of the control device defining a receivingchamber, the control device further including a power source and acontrol component, and a cartridge that includes a mouthpiece, a tank, aheating assembly, and a bottom cap, the mouthpiece having a proximal endand a distal end, the proximal end of the mouthpiece having an exitportal defined therethrough, the tank defining a proximal end and adistal end and being configured to contain a liquid composition, themouthpiece being configured to engage the proximal end of the tank, andthe bottom cap being configured to engage the distal end of the tank,wherein the cartridge is configured to be removably coupled with thereceiving chamber of the control device, wherein the heating assemblydefines a vaporization chamber and is configured to heat the liquidcomposition to generate an aerosol, wherein an inlet airflow is definedby a gap between the cartridge and the control device, wherein anaerosol path is defined through the tank and the exit portal of themouthpiece, and wherein the gap originates at an interface between anouter peripheral surface the mouthpiece and the control device.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theinterface is located proximate an outer peripheral surface of themouthpiece and a top edge of the outer wall of the housing.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theinlet airflow enters the cartridge through a single inlet channellocated in an approximate center of a bottom surface of the bottom cap.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theinlet channel located in the bottom cap has a nozzle-like shape.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thegap between the cartridge and the control device is established by aplurality of protuberances located on the control device.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theplurality of protuberances comprises a plurality of raised elongatebosses located on an upper frame of the control device.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thegap between the cartridge and the control device is established betweenthe outer housing and upper frame of the control device and themouthpiece, tank, and bottom cap of the cartridge.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thegap between the cartridge and the control device is further establishedbetween a recessed surface of the upper frame of the control device anda bottom surface of the bottom cap of the cartridge.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theheating assembly comprises a flat heating member and a liquid transportelement, and wherein the flat heating member and the liquid transportelement are installed in a curved orientation.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thecartridge further defines a vaporization chamber defined by the bottomcap and heating assembly.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theaerosol path originates at the vaporization chamber.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein inletair entering the vaporization chamber impinges on the heating membersubstantially perpendicularly thereto and spreads out substantiallyhorizontally.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thetank further defines a reservoir cavity configured to hold the liquidcomposition.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theaerosol path is defined by a pair of flow tubes located in the tank, andwherein at least a portion of the flow tubes are located on oppositesides of the reservoir cavity.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thereservoir cavity defines a closed proximate end and an open distal end.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theopen distal end of the reservoir cavity of the cartridge is sealed atleast in part by a separate base member.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thebase member includes a plurality of slots configured to provide liquidflow passages.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theaerosol path is further defined through an upper aerosol channel insertlocated between the tank and the exit portal of the mouthpiece.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thebottom cap of the cartridge includes a pair of inserts comprising aferromagnetic metal material.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein anupper frame of the control device includes a pair of magnets configuredto substantially align with the pair of metal inserts of the cartridge.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thecontrol device includes a pressure sensor, and wherein the cartridge andthe control device include a pressure path configured to signal anegative pressure to the pressure sensor.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thepressure path is defined at least in part by an offset pressure channeldefined in the bottom cap of the cartridge.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thepressure path is defined at least in part by a corresponding channel inan upper frame seal of the control device.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theupper frame seal includes a pair of channels such that the pressure pathis configured to be established in either of two rotational orientationsof the cartridge.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein thetop edge of the outer wall of the housing defines an opening that isgreater in size than the outer peripheral surface of the mouthpiece suchthat a maximum perimeter of the cartridge is wholly received within thereceiving chamber.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein whencoupled to the control device, a portion of the mouthpiece extends belowthe top edge of the outer wall of the housing and into the receivingchamber.

A cartridge for use with an aerosol delivery device, the cartridgecomprising a mouthpiece having a proximal end and a distal end, theproximal end having an exit portal defined therethrough, a tank having aproximal end and a distal end and being configured to contain a liquidcomposition therein, a heating assembly defining a vaporization chamberconfigured to heat the liquid composition to generate an aerosol, areservoir cavity configured to hold the liquid composition, and a bottomcap, wherein the mouthpiece is configured to engage the proximal end ofthe tank and the bottom cap is configured to engage the distal end ofthe tank, wherein an inlet airflow enters the cartridge through a singleinlet channel located in an approximate center of a bottom surface ofthe bottom cap, wherein an aerosol path is defined through the tank andthe exit portal of the mouthpiece, wherein the aerosol path is definedby a pair of flow tubes located in the tank, and wherein at least aportion of the flow tubes are located on opposite sides of the reservoircavity.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the inletchannel located in the bottom cap has a nozzle-like shape.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theheating assembly comprises a flat heating member and a liquid transportelement, and wherein the flat heating member and the liquid transportelement are installed in a curved orientation.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein thecartridge further defines a vaporization chamber defined by the bottomcap and heating assembly.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theaerosol path originates at the vaporization chamber.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein inlet airentering the vaporization chamber impinges on the heating membersubstantially perpendicularly thereto and spreads out substantiallyhorizontally.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein thereservoir cavity defines a closed proximate end and an open distal end.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the opendistal end of the reservoir cavity is sealed at least in part by aseparate base member.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the basemember includes a plurality of slots configured to provide liquid flowpassages.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theaerosol path is further defined through an upper aerosol channel insertlocated between the tank and the exit portal of the mouthpiece.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the bottomcap includes a pair of inserts comprising a ferromagnetic metalmaterial.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein a pressurepath is defined at least in part by an offset pressure channel definedin the bottom cap of the cartridge.

An aerosol delivery device comprising a control device that includes anouter housing defining an outer wall and having a proximal end and adistal end, the proximal end of the control device defining a receivingchamber, the control device further including a power source and acontrol component, and a cartridge that includes a mouthpiece, a tank,and a heating assembly, the tank being configured to contain a liquidcomposition, wherein the cartridge is configured to be removably coupledwith the receiving chamber of the control device, wherein the heatingassembly is configured to heat the liquid composition to generate anaerosol, wherein the heating assembly comprises a substantially planarheating member and a liquid transport element, and wherein the heatingmember is installed in a bowed orientation.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theheating member comprises a first end, a second end, and a heater loopconnecting the first end and the second end.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theheater loop comprises a serpentine pattern of connected heater tracesthat extend substantially transverse to a longitudinal axis of theheating member.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theserpentine pattern of heater traces comprises a plurality of splittraces located in a central area of the heating member.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theheater loop is configured to concentrate heat in the area of the heatingelement in contact with the liquid transport element.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, furthercomprising a base member into which the heating member and the liquidtransport element are disposed.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein atleast one edge of the heating member is configured to engage the basemember to facilitate the bowed orientation of the heating member.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, furthercomprising a pair of connectors configured to electrically connect thecartridge with one or more of the control component or the power source.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein theheating element includes a pair of contact holes configured to connectthe heating member to the connectors.

The aerosol delivery device of any preceding example implementation, orany combination of any preceding example implementations, wherein eachof the contact holes include one or more extensions that create aneffective inner diameter that is less than an outer diameter of themating connector.

A cartridge for use with an aerosol delivery device, the cartridgecomprising a mouthpiece, a tank configured to contain a liquidcomposition, and a heating assembly, wherein the heating assembly isconfigured to heat the liquid composition to generate an aerosol,wherein the heating assembly comprises a substantially planar heatingmember and a liquid transport element, and wherein the heating member isinstalled in a curved orientation.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theheating member comprises a first end, a second end, and a heater loopconnecting the first end and the second end.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the heaterloop comprises a serpentine pattern of connected heater traces thatextend substantially transverse to a longitudinal axis of the heatingmember.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theserpentine pattern of heater traces comprises a plurality of splittraces located in a central area of the heating member.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein the heaterloop is configured to concentrate heat in the area of the heatingelement in contact with the liquid transport element.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, further comprisinga base member into which the heating member and the liquid transportelement are disposed.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein at leastone edge of the heating member is configured to engage the base memberto facilitate the bowed orientation of the heating member. The cartridgeof any preceding example implementation, or any combination of anypreceding example implementations, further comprising a pair ofconnectors configured to electrically connect the cartridge with acontrol device.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein theheating element includes a pair of contact holes configured to connectthe heating member to the connectors.

The cartridge of any preceding example implementation, or anycombination of any preceding example implementations, wherein each ofthe contact holes include one or more extensions that create aneffective inner diameter that is less than an outer diameter of themating connector.

These and other features, aspects, and advantages of the disclosure willbe apparent from a reading of the following detailed descriptiontogether with the accompanying drawings, which are briefly describedbelow. The invention includes any combination of two, three, four, ormore of the above-noted embodiments as well as combinations of any two,three, four, or more features or elements set forth in this disclosure,regardless of whether such features or elements are expressly combinedin a specific embodiment description herein. This disclosure is intendedto be read holistically such that any separable features or elements ofthe disclosed invention, in any of its various aspects and embodiments,should be viewed as intended to be combinable unless the context clearlydictates otherwise.

BRIEF DESCRIPTION OF THE FIGURES

Having thus described the disclosure in the foregoing general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 illustrates a perspective view of an aerosol delivery device,according to example implementations of the present disclosure;

FIG. 2 illustrates a perspective view of a control device of an aerosoldelivery device, according to example implementations of the presentdisclosure;

FIG. 3 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to an example implementation ofthe present disclosure;

FIG. 4A illustrates a front view of a control device of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 4B illustrates a corresponding section view of the control deviceof FIG. 4A, according to an example implementation of the presentdisclosure;

FIG. 5A illustrates a side view of a control device of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 5B illustrates a corresponding section view of the control deviceof FIG. 5A, according to an example implementation of the presentdisclosure;

FIG. 6 illustrates a perspective partial section view of a controldevice of an aerosol delivery device, according to an exampleimplementation of the present disclosure;

FIG. 7 illustrates a perspective view of a cartridge of an aerosoldelivery device, according to example implementations of the presentdisclosure;

FIG. 8 illustrates an exploded perspective view of a cartridge of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 9A illustrates a front view of a cartridge of an aerosol deliverydevice, according to an example implementation of the presentdisclosure;

FIG. 9B illustrates a corresponding section view of the cartridge ofFIG. 8A, according to an example implementation of the presentdisclosure;

FIG. 10A illustrates a side view of a cartridge of an aerosol deliverydevice, according to an example implementation of the presentdisclosure;

FIG. 10B illustrates a corresponding section view of the cartridge ofFIG. 9A, according to an example implementation of the presentdisclosure;

FIG. 11 illustrates a perspective section view of an aerosol deliverydevice showing portions of the airflow and aerosol paths, according toan example implementation of the present disclosure;

FIG. 12A illustrates a side view of a cartridge of an aerosol deliverydevice showing portions of the airflow and aerosol paths, according toan example implementation of the present disclosure;

FIG. 12B illustrates a corresponding section view of the cartridge ofFIG. 12A, according to an example implementation of the presentdisclosure;

FIG. 13 illustrates a bottom perspective view of a cartridge of acontrol device showing portions of the airflow and aerosol paths,according to an example implementation of the present disclosure;

FIG. 14 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to an example implementation ofthe present disclosure;

FIG. 15 illustrates a front section view of a control device of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 16 illustrates a perspective view of an endcap assembly, accordingto an example implementation of the present disclosure;

FIG. 17A illustrates subassemblies of the control device of FIG. 14 ,according to an example implementation;

FIG. 17B illustrates subassemblies of the control device of FIG. 14 ,according to an example implementation;

FIG. 17C illustrates subassemblies of the control device of FIG. 14 ,according to an example implementation;

FIG. 18 illustrates a perspective view of a cartridge of an aerosoldelivery device, according to example implementations of the presentdisclosure;

FIG. 19 illustrates an exploded perspective view of a cartridge of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 20 illustrates a side section view of a cartridge of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 21A illustrates subassemblies of a cartridge of an aerosol deliverydevice, according to an example implementation of the presentdisclosure;

FIG. 21B illustrates subassemblies of a cartridge of an aerosol deliverydevice, according to an example implementation of the presentdisclosure;

FIG. 22 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to an example implementation ofthe present disclosure;

FIG. 23 illustrates a front section view of a control device of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 24 illustrates an exploded perspective view of a cartridge of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 25 illustrates a front section view of a cartridge of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 26 illustrates a side section view of a cartridge of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 27 illustrates a front section view of a cartridge and a controldevice of an aerosol delivery device, according to an exampleimplementation of the present disclosure;

FIG. 28 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to an example implementation ofthe present disclosure;

FIG. 29 illustrates a front section view of a control device of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 30 illustrates a perspective partial section view of a controldevice of an aerosol delivery device, according to an exampleimplementation of the present disclosure;

FIG. 31 illustrates a perspective view of an endcap assembly, accordingto an example implementation of the present disclosure;

FIG. 32 illustrates an exploded perspective view of a cartridge of anaerosol delivery device, according to an example implementation of thepresent disclosure;

FIG. 33 illustrates a front section view of a cartridge of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 34 illustrates a side section view of a cartridge of an aerosoldelivery device, according to an example implementation of the presentdisclosure;

FIG. 35 illustrates a side section view of a control device of anaerosol delivery device showing airflow through the control device,according to an example implementation of the present disclosure;

FIG. 36 illustrates an angled side section view of a cartridge of anaerosol delivery device showing air and aerosol flow paths, according toan example implementation of the present disclosure;

FIG. 37 illustrates an angled front section view of a cartridge of anaerosol delivery device showing air and aerosol flow paths, according toan example implementation of the present disclosure; and

FIG. 38 illustrates a bottom perspective view of a cartridge of anaerosol delivery device showing portions of the air and aerosol flowpaths, according to an example implementation of the present disclosure.

DETAILED DESCRIPTION

The present disclosure will now be described more fully hereinafter withreference to example embodiments thereof. These example embodiments aredescribed so that this disclosure will be thorough and complete, andwill fully convey the scope of the disclosure to those skilled in theart. Indeed, the disclosure may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein;rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. As used in the specification, andin the appended claims, the singular forms “a”, “an”, “the”, includeplural referents unless the context clearly dictates otherwise.

As described hereinafter, embodiments of the present disclosure relateto aerosol delivery devices or vaporization devices, said terms beingused herein interchangeably. Aerosol delivery devices according to thepresent disclosure use electrical energy to heat a material (preferablywithout combusting the material to any significant degree and/or withoutsignificant chemical alteration of the material) to form an inhalablesubstance; and components of such devices have the form of articles thatmost preferably are sufficiently compact to be considered hand-helddevices. That is, use of components of preferred aerosol deliverydevices does not result in the production of smoke - i.e., fromby-products of combustion or pyrolysis of tobacco, but rather, use ofthose preferred systems results in the production of vapors resultingfrom volatilization or vaporization of certain components incorporatedtherein. In preferred embodiments, components of aerosol deliverydevices may be characterized as electronic cigarettes, and thoseelectronic cigarettes most preferably incorporate tobacco and/orcomponents derived from tobacco, and hence deliver tobacco derivedcomponents in aerosol form.

Aerosol delivery devices may provide many of the sensations (e.g.,inhalation and exhalation rituals, types of tastes or flavors,organoleptic effects, physical feel, use rituals, visual cues such asthose provided by visible aerosol, and the like) of smoking a cigarette,cigar, or pipe that is employed by lighting and burning tobacco (andhence inhaling tobacco smoke), without any substantial degree ofcombustion of any component thereof. For example, the user of an aerosolgenerating device of the present disclosure can hold and use that piecemuch like a smoker employs a traditional type of smoking article, drawon one end of that piece for inhalation of aerosol produced by thatpiece, take or draw puffs at selected intervals of time, and the like.

Aerosol delivery devices of the present disclosure also can becharacterized as being vapor-producing articles or medicament deliveryarticles. Thus, such articles or devices can be adapted so as to provideone or more substances (e.g., flavors and/or pharmaceutical activeingredients) in an inhalable form or state. For example, inhalablesubstances can be substantially in the form of a vapor (i.e., asubstance that is in the gas phase at a temperature lower than itscritical point). Alternatively, inhalable substances can be in the formof an aerosol (i.e., a suspension of fine solid particles or liquiddroplets in a gas). For purposes of simplicity, the term “aerosol” asused herein is meant to include vapors, gases, and aerosols of a form ortype suitable for human inhalation, whether or not visible, and whetheror not of a form that might be considered to be smoke-like.

Aerosol delivery devices of the present disclosure most preferablycomprise some combination of a power source (i.e., an electrical powersource), at least one control component (e.g., means for actuating,controlling, regulating and ceasing power for heat generation, such asby controlling electrical current flow from the power source to othercomponents of the article - e.g., a microcontroller or microprocessor),a heater or heat generation member (e.g., an electrical resistanceheating element or other component, which alone or in combination withone or more further elements may be commonly referred to as an“atomizer”), a liquid composition (e.g., commonly an aerosol precursorcomposition liquid capable of yielding an aerosol upon application ofsufficient heat, such as ingredients commonly referred to as “smokejuice,” “e-liquid” and “e-juice”), and a mouthpiece or mouth region forallowing draw upon the aerosol delivery device for aerosol inhalation(e.g., a defined airflow path through the article such that aerosolgenerated can be withdrawn therefrom upon draw).

More specific formats, configurations and arrangements of componentswithin the aerosol delivery devices of the present disclosure will beevident in light of the further disclosure provided hereinafter.Additionally, the selection and arrangement of various aerosol deliverydevice components can be appreciated upon consideration of thecommercially available electronic aerosol delivery devices, such asthose representative products referenced in the background art sectionof the present disclosure.

In various implementations, the present disclosure relates to aerosoldelivery devices and cartridges and control devices that togethercomprise an aerosol delivery device. As will be described in more detailbelow, in various implementations the aerosol delivery device may haveimproved connectively, airflow, and/or aerosol paths through the device.

An example implementation of an aerosol delivery device 100 of thepresent disclosure is shown in FIG. 1 . As illustrated, the aerosoldelivery device 100 includes a control device 200 and a removablecartridge 300. Although only one cartridge is shown in the depictedimplementation, it should be understood that, in variousimplementations, the aerosol delivery device 100 may comprise aninterchangeable system. For example, in one or more implementations, asingle control device may be usable with a plurality of differentcartridges. Likewise, in one or more implementations, a single cartridgemay be usable with a plurality of different control devices.

FIG. 2 illustrates a perspective view of the control device 200, andFIG. 3 illustrates an exploded perspective view of the control device200. As shown in the figures, the control device 200 of the depictedimplementation generally includes a housing 202 defining an outer wall204, an upper frame 206, an upper frame seal 208, a pressure sensor seal210, a lower frame 212, a control component 214, a battery 216, avibration motor 218, a motor housing 220, a pin seal 222, an end cap224, and a light diffuser 226. The arrangement of these components isillustrated in FIGS. 4A and 4B, and FIGS. 5A and 5B. In particular, FIG.4A illustrates a front view of the control device 200, and FIG. 4Billustrates a corresponding section view of the control device 200.Likewise, FIG. 5A illustrates a side view of the control device 200, andFIG. 5B illustrates a corresponding section view of the control device200. As illustrated in the figures, the upper frame 206 of the controldevice 200 defines a cartridge receiving chamber 230 within which acartridge may be coupled. The control device 200 also includes a pair ofopposite indication windows 232 that are defined through the outer wall204 of the housing 202, as well as through the upper frame 206. As willbe described in more detail below, in various implementations theindication windows 232 may provide a user with the ability to view oneor more components (and/or conditions thereof) of an installedcartridge. It will be appreciated, however, that the illustratedindication windows 232 are provided by way of example and not by way oflimitation. For example, alternative implementations may include anindication window having a different shape than that illustrated. Asanother example, some implementations may include only a singleindication window. In still other implementations, there need not be anyindication windows. In the depicted implementation, the upper frame 206and the housing 202 represent different parts; however, in otherimplementations, the upper frame and the housing may be continuouslyformed such that they comprise the same part.

In the depicted implementation, the housing 202 comprises a metalmaterial, such as, for example, aluminum; however, in otherimplementations the housing may comprise a metal alloy material, and instill other implementations the housing may comprise a molded plasticmaterial. In the depicted implementation, one or more of the housing202, upper frame 206, lower frame 212, and end cap 224 may be made of amolded polymer material, such as, for example, a molded plastic material(e.g., polybutylene terephthalate (PBT), acrylonitrile butadiene styrene(ABS), polyethylene, polycarbonate, Polyamide (Nylon), high impactpolystyrene, polypropylene, and combinations thereof). In otherimplementations, one or more of these components may be made of othermaterials, including, for example, metal materials (e.g., aluminum,stainless steel, metal alloys, etc.), glass materials, ceramic materials(e.g., alumina, silica, mullite, silicon carbide, silicon nitride,aluminum nitride, etc.), composite materials, and/or any combinationsthereof.

In the depicted implementation, the lower frame 212 is configured tocontain the battery 216 in an interior area thereof. In the depictedimplementation, the battery may comprise a lithium polymer (LiPo)battery; however various other batteries may be suitable. Some otherexamples of batteries that can be used according to the disclosure aredescribed in U.S. Pat. App. Pub. No. 2010/0028766 to Peckerar et al.,the disclosure of which is incorporated herein by reference in itsentirety. In some implementations, other types of power sources may beutilized. For example, in various implementations a power source maycomprise a replaceable battery or a rechargeable battery, solid-statebattery, thin-film solid-state battery, rechargeable supercapacitor orthe like, and thus may be combined with any type of rechargingtechnology, including connection to a wall charger, connection to a carcharger (e.g., cigarette lighter receptacle, USB port, etc.), connectionto a computer, such as through a universal serial bus (USB) cable orconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a USBconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C as may be implemented ina wall outlet, electronic device, vehicle, etc.), connection to aphotovoltaic cell (sometimes referred to as a solar cell) or solar panelof solar cells, a wireless charger, such as a charger that usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)), or a wireless radio frequency (RF) based charger, andconnection to an array of external cell(s) such as a power bank tocharge a device via a USB connector or a wireless charger. An example ofan inductive wireless charging system is described in U.S. Pat. App.Pub. No. 2017/0112196 to Sur et al., which is incorporated herein byreference in its entirety. In further implementations, a power sourcemay also comprise a capacitor. Capacitors are capable of dischargingmore quickly than batteries and can be charged between puffs, allowingthe battery to discharge into the capacitor at a lower rate than if itwere used to power the heating member directly. For example, asupercapacitor - e.g., an electric double-layer capacitor (EDLC) - maybe used separate from or in combination with a battery. When used alone,the supercapacitor may be recharged before each use of the article.Thus, the device may also include a charger component that can beattached to the smoking article between uses to replenish thesupercapacitor. Examples of power supplies that include supercapacitorsare described in U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,which is incorporated herein by reference in its entirety.

The aerosol delivery device 100 of the depicted implementation includesa control mechanism in the form of the control component 214, which isconfigured, in part, to control the amount of electric power provided tothe heating member of the cartridge. Although other configurations arepossible, the control component 214 of the depicted implementationcomprises a circuit board 234 (e.g., a printed circuit board (PCB)) thatincludes both rigid and flexible portions. In particular, the circuitboard 234 of the depicted implementation includes a rigid centralsection 215 and two rigid end sections comprising a proximal end section217 and a distal end section 219, with each of the end sections 217, 219being connected to the central section 215 by a respective flexibleconnection. In such a manner, when the lower frame 212, battery 216, andcircuit board 234 are assembled into the control device 200, the centralsection 215 of the circuit board 234 is configured to be disposedproximate a major surface of the battery 216, and the two end sections217, 219 are configured to be disposed substantially perpendicular tothe central section 215. In particular, the proximal end section 217 ofthe circuit board 234 is configured to extend over the top of the lowerframe 212, and the distal end section 219 is configured to extend overthe bottom of the lower frame 212. The lower frame 212 of the controldevice 200 is also configured to contain the motor housing 220, intowhich the vibration motor 218 is received. In various implementations,the vibration motor 218 may provide haptic feedback relating to variousoperations of the device 100.

The central section 215 of the depicted implementation also includes anindicator in the form of a light source 221. In some implementations,the light source may comprise, for example, at least one light emittingdiode (LED) capable of providing one or more colors of light. In otherimplementations, the light source may be configured to illuminate inonly one color, while in other implementations, the light source may beconfigured to illuminate in variety of different colors. In still otherimplementations, the light source may be configured to provide whitelight. In the depicted implementation, the light source 221 comprises anRGB (red, green, blue) LED that is configured to provide a variety ofcolors of light, including white light. The central section 215 of thedepicted circuit board 234 also includes electrical contacts 223 thatare configured to operatively connect the circuit board 234 to thevibration motor 218. Other types of electronic components, structuresand configurations thereof, features thereof, and general methods ofoperation thereof, are described in U.S. Pat. Nos. 4,735,217 to Gerth etal.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.;6,040,560 to Fleischhauer et al.; 7,040,314 to Nguyen et al. and8,205,622 to Pan; U.S. Pat. App. Pub. Nos. 2009/0230117 to Fernando etal., 2014/0060554 to Collet et al., and 2014/0270727 to Ampolini et al.;and U.S. Pat. App. Pub. No. 2015/0257445 to Henry et al.; which areincorporated herein by reference. Yet other features, controls orcomponents that can be incorporated into aerosol delivery devices of thepresent disclosure are described in U.S. Pat. Nos. 5,967,148 to Harriset al.; 5,934,289 to Watkins et al.; U.S. Pat. No. 5,954,979 to Countset al.; 6,040,560 to Fleischhauer et al.; 8,365,742 to Hon; 8,402,976 toFernando et al.; U.S. Pat. App. Pub. Nos. 2010/0163063 to Fernando etal.; 2013/0192623 to Tucker et al.; 2013/0298905 to Leven et al.;2013/0180553 to Kim et al., 2014/0000638 to Sebastian et al.,2014/0261495 to Novak et al., and 2014/0261408 to DePiano et al.; whichare incorporated herein by reference in their entireties.

In the depicted implementation, the light source 221 is covered by thelight diffuser 226, a portion of which is configured to be received bythe end cap 224. In such a manner, when assembled, the light diffuser226 is positioned in or proximate an aperture 225 defined in the outerwall 204 of the housing 202 and proximate a distal end thereof. In thedepicted implementation, the aperture 225 comprises a narrow, elongateopening; however, in other implementations, the aperture may be providedin any desired shape and may be positioned at any location on thecontrol device 200. In some implementations, the light diffuser 226 maycomprise a transparent or translucent member configured to allow a userto view the light source 221 from the outside of the housing 202. In thedepicted implementation, the light diffuser 226 may be made of a moldedpolymer material, such as, for example, a molded plastic material (e.g.,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof), although other materials, including glass, arepossible. In various implementations, further indicators (e.g., otherhaptic feedback components, an audio feedback component, or the like)can be included in addition to or as an alternative to the indicatorsincluded in the depicted implementation. Additional representative typesof components that yield visual cues or indicators, such as LEDcomponents, and the configurations and uses thereof, are described inU.S. Pat. Nos. 5,154,192 to Sprinkel et al.; 8,499,766 to Newton and8,539,959 to Scatterday; U.S. Pat. App. Pub. No. 2015/0020825 toGalloway et al.; and U.S. Pat. App. Pub. No. 2015/0216233 to Sears etal.; which are incorporated herein by reference in their entireties.

Although other configurations are possible, the proximal end section 217of the circuit board 234 of the depicted implementation includes a pairof conductive pins 236A, 236B, as well as a pressure sensor 240. In thedepicted implementation, the conductive pins 236A, 236B comprisespring-loaded pins (e.g., electrical pogo pins) that extend through theupper frame 206 such that portions of the ends of the pins 236A, 236Bextend into the cartridge receiving chamber 230 and are biased in thatposition due to the force of the internal springs of the conductive pins236A, 236B. In such a manner, when a cartridge is coupled with thecontrol device 200, the conductive pins 236A, 236B are configured tocontact corresponding features of the cartridge and deflect downward(e.g., toward the lower frame 212) against the force of the springs,thus operatively connecting the installed cartridge with the controlcomponent 214 and the battery 216. In the depicted implementation, theconductive pins 236A, 236B comprise gold plated metal pins; however,other materials or combinations of materials, which may also includecoatings and/or platings of electrically conductive materials, arepossible. Examples of electrically conductive materials, include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. Although other profiles are possible, the ends ofthe conductive pins 236A, 236B of the depicted implementation have arounded profile such that deflection of the conductive pins 236A, 236Bis facilitated when a cartridge is inserted into the cartridge receivingchamber 230. In other implementations, the conductive pins may bepositioned in other locations of the cartridge receiving chamber 230,such as, for example, proximate the top of the cartridge receivingchamber 230. In other implementations, the conductive pins may bepositioned at a point on the sides of the upper frame 206 between theproximal end of the outer housing 202 and the bottom wall of the upperframe 206. Further, in still other implementations the conductive pinsmay be positioned between a midpoint of the sidewalls and the proximalend of the outer housing 202 (i.e., in an upper half of the sidewalls).Alternatively, the conductive pins may be positioned between a midpointof the sidewalls and the bottom wall of the inner frame wall (e.g., in alower half of the sidewalls). Moreover, in still other implementations,the conductive pins may be present at any position of the upper frame206.

In various implementations, the aerosol delivery device 100 may includean airflow sensor, pressure sensor, or the like. As noted above, thecontrol component 214 of the depicted implementation includes a pressuresensor 240, which is positioned proximate and below the cartridgereceiving chamber 230. The position and function of the pressure sensor240 of the depicted implementation will be described below; however, inother implementations an airflow or pressure sensor may be positionedanywhere within the control device 200 so as to subject to airflowand/or a pressure change that can signal a draw on the device and thuscause the battery 216 to delivery power to the heating member of thecartridge 300. Various configurations of a printed circuit board and apressure sensor, for example, are described in U.S. Pat. Pub. No.2015/0245658 to Worm et al., the disclosure of which is incorporatedherein by reference in its entirety. In the absence of an airflowsensor, pressure sensor, or the like, an aerosol delivery device may beactivated manually, such as via a pushbutton that may be located on thecontrol device and/or the cartridge. For example, one or morepushbuttons may be used as described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., which is incorporated herein by referencein its entirety. Likewise, a touchscreen may be used as described inU.S. Pat. App. Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference in its entirety. As afurther example, components adapted for gesture recognition based onspecified movements of the aerosol delivery device may be used as aninput. See U.S. Pat. App. Pub. No. 2016/0158782 to Henry et al., whichis incorporated herein by reference in its entirety.

Although not included in the depicted implementation, someimplementations may include other types of input elements, which mayreplace or supplement an airflow or pressure sensor. The input may beincluded to allow a user to control functions of the device and/or foroutput of information to a user. Any component or combination ofcomponents may be utilized as an input for controlling the function ofthe device. In some implementations, an input may comprise a computer orcomputing device, such as a smartphone or tablet. In particular, theaerosol delivery device may be wired to the computer or other device,such as via use of a USB cord or similar protocol. The aerosol deliverydevice may also communicate with a computer or other device acting as aninput via wireless communication. See, for example, the systems andmethods for controlling a device via a read request as described in U.S.Pat. App. Pub. No. 2016/0007561 to Ampolini et al., the disclosure ofwhich is incorporated herein by reference in its entirety. In suchembodiments, an APP or other computer program may be used in connectionwith a computer or other computing device to input control instructionsto the aerosol delivery device, such control instructions including, forexample, the ability to form an aerosol of specific composition bychoosing the nicotine content and/or content of further flavors to beincluded. Additional representative types of sensing or detectionmechanisms, structure and configuration thereof, components thereof, andgeneral methods of operation thereof, are described in U.S. Pat. Nos.5,261,424 to Sprinkel, Jr.; 5,372,148 to McCafferty et al.; and PCT WO2010/003480 to Flick; which are incorporated herein by reference intheir entireties.

In the depicted implementation, the pressure sensor seal 210 isconfigured to cover the pressure sensor 240 to protect it from anyliquid and/or aerosol from an installed cartridge. In addition, thepressure sensor seal 210 of the depicted implementation is configured toseal the conductive pins 236A, 236B. In such a manner, the pressuresensor seal 210 of the depicted implementation may be made of siliconerubber, boron nitride (BN) rubber, natural rubber, thermoplasticpolyurethane, or another resilient material. In the depictedimplementation, the upper frame seal 208 is configured to be positionedproximate and above the pressure sensor seal 210, such that a pair ofupper frame seal tubes 209A, 209B (see FIG. 6 ) of the upper frame seal208 extend through the upper frame 206 and into the cartridge receivingchamber 230. The upper frame seal 208 of the depicted implementation mayalso be made of a silicone, thermoplastic polyurethane, or anotherresilient material.

Although other configurations are possible, the distal end section 219of the circuit board 234 includes the external connection element 238.In various implementations, the external connection element 238 may beconfigured for connecting to an external connector and/or a dockingstation or other power or data source. For example, in someimplementations an external connector may comprise first and secondconnector ends that may be interconnected by a union, which may be, forexample, a cord of variable length. In some implementations, the firstconnector end may be configured for electrical and, optionally,mechanical connection with the device (100,200), and the secondconnector end may be configured for connection to a computer or similarelectronic device or for connection to a power source. An adaptorincluding a USB connector at one end and a power unit connector at anopposing end is disclosed in U.S. Pat. App. Pub. No. 2014/0261495 toNovak et al., which is incorporated herein by reference in its entirety.In the depicted implementation, the pin seal 222 is configured to sealthe interface between the external connection element 238 and the endcap 224. In such a manner, the pin seal 222 of the depictedimplementation may be made of a silicone, thermoplastic polyurethane, oranother resilient material. In the depicted implementation, one or morepins of the external connection element 238 may extend through the endcap 224 of the control device as noted above.

In various implementations, the control device may include one or morecomponents configured to meet battery outgassing requirements under UL8139. For example, the control device may include an end cap configuredto eject in the event that sudden pressurization occurs within thecontrol device enclosure. In one implementation, the end cap may includeretaining pins that extend substantially perpendicularly from a wall ofthe end cap. The retaining pins may be configured to mate with receivingfeatures (e.g., holes) in a frame of the control device to establish afriction fit or press fit that may be overcome if an internal pressurewithin the control device housing exceeds a defined internal pressure.

FIG. 6 illustrates a perspective partial section view of a controldevice of an aerosol delivery device. In particular, FIG. 6 illustratesa partial section view of the housing 202, upper frame 206, upper frameseal 208, pressure sensor seal 210, pressure sensor 240, and lower frame212 of the control device 200. As shown in the figure, a portion of theconductive pins 236A, 236B of the control component 214 extend throughthe upper frame 206. In particular, a portion of the conductive pins236A, 236B of the depicted implementation, which as noted above comprisespring-loaded contacts, extend through a recessed surface 244 of theupper frame 206 and into the cartridge receiving chamber 230. Inaddition, a portion of the upper frame seal tubes 209A, 209B (whichdefine respective seal tube channels 211A, 211B) of the upper frame seal208 extend through the upper frame 206 and are exposed in the cartridgereceiving chamber 230. As will be described in more detail below,regardless of the orientation of an installed cartridge, the conductivepins 236A, 236B and one of the upper frame seal tubes 209A, 209B areconfigured to substantially align with corresponding features of aninstalled cartridge.

As also shown in the figure, the upper frame 206 includes a pair ofmagnets 246A, 246B that are also exposed in the cartridge receivingchamber 230. In various implementations, the magnets 246A, 246B maycomprise any type of magnets, including rare earth magnets. For example,in some implementations, one or more of the magnets may compriseNeodymium magnets (also known as NdFeB, NIB, or Neo magnets). In variousimplementations, different grades of Neodymium magnets may be used,including, for example, N35, N38, N40, N42, N45, N48, N50, and/or N52grades. In other implementations, one or more of the magnets maycomprise Samarium Cobalt magnets (also known as SmCo magnets). In stillother implementations, one or more of the magnets may compriseCeramic/Ferrite magnets. In other implementations, one or more of themagnets may comprise Aluminum-Nickel-Cobalt (AlNiCo) magnets. In any ofthe foregoing implementations, one or more of the magnets may be platedand/or coated. For example, in some implementations, one or more of themagnets may be coated with nickel. In other implementations, one or moremagnets may be coated with one or more of zinc, tin, copper, epoxy,silver and/or gold. In some implementations, one or more of the magnetsmay be coated with combinations of these materials. For example, in oneimplementation, one or more of the magnets may be coated with nickel,copper, and nickel again. In another implementation, one or more of themagnets may be coated with nickel, copper, nickel, and a top coating ofgold.

In the depicted implementation, each magnet 246A, 246B is substantiallysurrounded by a respective location feature 248A, 248B of the upperframe 206, wherein the location features 248A, 248B also extend into thecartridge receiving chamber 230. Likewise, each upper frame seal tube209A, 209B of the upper frame seal 208 is substantially surrounded by arespective location feature 250A, 250B. As will be discussed in moredetail below, one or more of the location features 248A, 248B, 250A,250B of the upper frame 206 are configured as stopping or verticallocating features for an installed cartridge and are thus configured toposition the cartridge 300 with respect to the recessed surface 244 ofthe upper frame 206 of the control device 200.

As noted above, a portion of the cartridge 300 is configured to becoupled with the cartridge receiving chamber 230 of the inner frame 206of the control device 200 such that mechanical and electricalconnections are created between the cartridge 300 and the control device200. In particular, when the cartridge 300 of the depictedimplementation is coupled with the upper frame 206 of the control device200, a magnetic connection is created between the magnets 246A, 246Blocated in the upper frame 206 and corresponding features of thecartridge 300. In addition, when the cartridge 300 of the depictedimplementation is coupled with the inner frame 206, an electricalconnection is created between the pair conductive pins 236A, 236B of thecontrol device 200 and corresponding features of the cartridge 300. Assuch, when the cartridge 300 is received in the receiving chamber 230 ofthe control device 200, the cartridge 300 may be operatively connectedto the control component 214 and the battery 216 of the control device200. Thus, when the cartridge 300 of the depicted implementation iscoupled with the control device 200, the cartridge 300 is mechanicallybiased into connection with the control device 200 such that electricalconnection is maintained between the cartridge and the control device.It should be understood that for the purposes of the present disclosure,the term “operatively connected” and other related forms thereof shouldbe interpreted broadly so as to encompass components that are directlyconnected and/or connected via one or more additional components.

FIG. 7 illustrates a perspective view of the cartridge 300, and FIG. 8illustrates an exploded perspective view of the cartridge 300. Althoughother configurations are possible, the cartridge 300 of the depictedimplementation generally includes a mouthpiece 302, a mouthpiece insert304, an upper aerosol channel insert 306, an upper cartridge seal 308, atank 310 that defines a tank wall 311, a lower cartridge seal 312, abase member 314, a liquid transport element (e.g., a wick) 316, aheating member 318, a pair of heater connectors 320A, 320B, a pair ofO-ring seals 322A, 322B, a pair of metal inserts 324A, 324B, and abottom cap 326. The arrangement of these components is illustrated inFIGS. 9A, 9B, 10A, and 10B. In particular, FIG. 9A illustrates a frontview of the cartridge 300, and FIG. 9B illustrates a correspondingsection view of the cartridge 300. Likewise, FIG. 10A illustrates a sideview of the cartridge 300, and FIG. 10B illustrates a correspondingsection view of the cartridge 300.

As shown in the figures, the mouthpiece 302 of the depictedimplementation defines a proximal end and a distal end, with theproximal end of the mouthpiece 302 defining an exit portal 315 therein.In the depicted implementation, the mouthpiece insert 304 is configuredto be located proximate the proximal end of the mouthpiece 302 such thatit extends through the exit portal 315 thereof. In the depictedimplementation, mouthpiece 302 and the mouthpiece insert 304 may be madeof a molded polymer material, such as, for example, a molded plasticmaterial (e.g., polypropylene, acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,and combinations thereof), although other materials are possible. Themouthpiece insert 304 of the depicted implementation includes a flangefeature on a lower portion thereof such that the mouthpiece insert 304may be installed from inside the mouthpiece 302 and may be configuredfor a press or snap-fit connection with the exit portal 315. In otherimplementations, other attachment methods are possible (e.g., viaadhesives, heat staking/welding, ultrasonic welding, etc.). In stillother implementations, the mouthpiece and mouthpiece insert may beconstructed using an insert molding or overmolding process such that themouthpiece 302 and the mouthpiece insert 304 comprise a unitary part.The mouthpiece 302 of the depicted implementation is configured to besecured to the tank 310 via snap features included on one or both of themouthpiece 302 and tank 310; however, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.).

In some implementations, the mouthpiece insert may exhibit a colorassociated with a distinctive characteristic of the cartridge. Forexample, in some implementations a cartridge of the present disclosuremay include a liquid composition that includes a distinctivecharacteristic such as, for example, a particular flavorant (asdiscussed infra), or a specific strength of nicotine, although anycharacteristic of the cartridge may be considered a distinctivecharacteristic. For the purposes of the current description, the term“color” should be interpreted broadly, for example covering any color orany shade of the same color. It should also be noted that in someimplementations, certain colors may be commonly associated withparticular distinctive characteristics (e.g., the color green may beassociated with a mint flavorant, and the color red may be associatedwith an apple flavorant); however, in other implementations, certaincolors may be associated with particular distinctive characteristicsaccording to an index or guide, which may be provided or made availableto a user. Examples of distinctive characteristics are described in U.S.Pat. App. Serial No. 16/171,920, titled Aerosol Delivery Device withFlavor Indicator, which is incorporated herein by reference in itsentirety.

The tank 310 of the depicted implementation defines a proximal end and adistal end, wherein the mouthpiece 302 is configured to engage theproximal end of the tank 310 and the bottom cap 326 is configured toengage the distal end of the tank 310. In the depicted implementation,the tank 310 also defines a reservoir cavity 328 that includes a closedproximal end and an open distal end. As such, the reservoir cavity 328of the tank 310 is configured to contain a liquid composition (e.g., ane-liquid or aerosol precursor composition) therein. The closed proximalend of the reservoir cavity 328 allows the cavity to create a reliableseal on the top side of the liquid composition column. This may preventthe seepage/entry of air into the reservoir cavity from the top end whenthe cartridge is held upright. This may also prevent air from enteringfrom the top of the liquid composition column, which may create a vacuumand may reduce the potential of the liquid composition to leak from thebottom of the tank through the liquid transport element or otherpassages.

Although other configurations are possible, in the depictedimplementation a pair of internal aerosol flow tubes 333A, 333B aredefined on opposite sides of the reservoir cavity 328 of the tank 310.In the case of an injection molded tank 310, the internal aerosol flowtubes 333A, 333B are configured to be molded therein. As will bedescribed in more detail below, aerosol produced in a vaporizationchamber of the cartridge 300 is configured to travel through the aerosolflow tubes 333A, 333B for delivery to a user.

In the depicted implementation, the tank wall 311 is configured to betransparent or translucent so that the liquid composition containedtherein may be visible externally. As such, in the depictedimplementation the entire tank wall 311 is configured to be transparentor translucent. Alternatively, in some implementations, only a portionof the tank wall or only a single side of the tank wall may betransparent or translucent while the remaining portions of the tank wallmay be substantially opaque. In other implementations, the tank wall maybe substantially opaque, and a strip extending from the proximal end ofthe tank to the distal end of the tank may be transparent ortranslucent. In further implementations, the tank wall may be colored.In some implementations, the color can be configured so that the liquidcomposition within the tank is still visible, such by using atransparent or translucent outer tank wall. In other implementations,the tank wall can be configured so that the outer tank wall hassubstantially opaque color. In the depicted implementation, the tank 310may be made of a molded polymer material, such as, for example, a moldedplastic material (e.g., a copolyester material, such as, for example,Tritan™ copolyester, acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof), although other materials,including glass, are possible.

The indication window 232 of the depicted implementation of the controldevice 200 is configured so that at least a portion of the tank 310 andat least a portion of the bottom cap 326 are visible when the cartridge300 is engaged with the control device 200. As noted above, in someimplementations at least a portion of the tank wall 311 may beconfigured to be at least partially transparent or translucent so thatthe liquid composition contained therein is visible externally. Thus,the relative amount of any liquid composition present in the tank 310may be visible through the indication window 232 when the cartridge 300is engaged with the control device 200. As illustrated in FIGS. 1-6 ,the indication window 232 of the depicted implementation is located nearthe proximal end of the control device 200 and is configured as anelongate oval shaped cut-out in the outer wall 204 of the housing 202and the upper frame 206 of the control device 200. It should beunderstood that in other implementations, the indication window may haveany other shapes and/or locations. For example, in some implementationsthe indication window may be configured as a notch extending from theproximal end of the outer wall of the control device a distance towardthe distal end of the device. In still other implementations, theindication window may be configured so as not to have any open bordersand thus may expressly exclude a notch configuration as noted above. Insome implementations, the indication window may be completely open, andin other implementations, the indication window may have a transparentmember (e.g., glass or plastic) positioned in the opening defined by theindication window or covering the indication window on one or both ofthe inner surface and outer surface of the outer wall of the controldevice. It should be understood that in some implementations, theindication window may be formed in part by the cartridge and in part bythe control device. For example, in some implementations, the cartridgemay include a portion of the indication window (e.g., a top portion ofan indication window), and the control device may include a separateportion of the indication window (e.g., a bottom portion of theindication window).

Although other configurations are possible, in the depictedimplementation the proximal end of the tank 310 is configured to receivethe upper cartridge seal 308, which is configured to form asubstantially air tight and liquid tight seal between the tank 310 andthe mouthpiece 302. As such, the upper cartridge seal 308 may be made ofsilicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material. In thedepicted implementation, the upper cartridge seal 308 is also configuredto receive and seal the upper aerosol channel insert 306 (see also FIG.11 ).

For aerosol delivery systems that are characterized as electroniccigarettes, the aerosol precursor composition may incorporate tobacco orcomponents derived from tobacco. In one regard, the tobacco may beprovided as parts or pieces of tobacco, such as finely ground, milled orpowdered tobacco lamina. Tobacco beads, pellets, or other solid formsmay be included, such as described in U.S. Pat. App. Pub. No.2015/0335070 to Sears et al., the disclosure of which is incorporatedherein by reference. In another regard, the tobacco may be provided inthe form of an extract, such as a spray dried extract that incorporatesmany of the water soluble components of tobacco. Alternatively, tobaccoextracts may have the form of relatively high nicotine content extracts,which extracts also incorporate minor amounts of other extractedcomponents derived from tobacco. In another regard, components derivedfrom tobacco may be provided in a relatively pure form, such as certainflavoring agents that are derived from tobacco. In one regard, acomponent that is derived from tobacco, and that may be employed in ahighly purified or essentially pure form, is nicotine (e.g.,pharmaceutical grade nicotine).

In the depicted implementation, the liquid composition, sometimereferred to as an aerosol precursor composition or a vapor precursorcomposition or “e-liquid”, may comprise a variety of componentsincluding, by way of example, a polyhydric alcohol (e.g., glycerin,propylene glycol, or a mixture thereof), nicotine, tobacco, tobaccoextract, and/or flavorants. Representative types of aerosol precursorcomponents and formulations also are set forth and characterized in U.S.Pat. No. 7,217,320 to Robinson et al. and U.S. Pat. App. Pub. Nos.2013/0008457 to Zheng et al.; 2013/0213417 to Chong et al.; 2014/0060554to Collett et al.; 2015/0020823 to Lipowicz et al.; and 2015/0020830 toKoller, as well as WO 2014/182736 to Bowen et al., the disclosures ofwhich are incorporated herein by reference in their entireties. Otheraerosol precursors that may be employed include the aerosol precursorsthat have been incorporated in VUSE® products by R. J. Reynolds VaporCompany, the BLU™ products by Fontem Ventures B.V., the MISTIC MENTHOLproduct by Mistic Ecigs, MARK TEN products by Nu Mark LLC, the JUULproduct by Juul Labs, Inc., and VYPE products by CN Creative Ltd. Alsodesirable are the so-called “smoke juices” for electronic cigarettesthat have been available from Johnson Creek Enterprises LLC. Stillfurther example aerosol precursor compositions are sold under the brandnames BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THEVAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEYJONES MAINLINE RESERVE, MITTEN VAPORS, DR. CRIMMY’S V-LIQUID, SMILEY ELIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFEVAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THEJUICE MAN.

The amount of aerosol precursor that is incorporated within the aerosoldelivery system is such that the aerosol generating piece providesacceptable sensory and desirable performance characteristics. Forexample, it is highly preferred that sufficient amounts of aerosolforming material (e.g., glycerin and/or propylene glycol), be employedin order to provide for the generation of a visible mainstream aerosolthat in many regards resembles the appearance of tobacco smoke. Theamount of aerosol precursor within the aerosol generating system may bedependent upon factors such as the number of puffs desired per aerosolgenerating piece. In the depicted implementation, the reservoir cavity328 is configured to hold approximately 1.5 mL of aerosol precursorcomposition. In other embodiments, the reservoir cavity 328 isconfigured to hold about 1 ml or more, about 2 ml or more, about 5 ml ormore, or about 10 ml or more of the aerosol precursor composition.

In some implementations, the liquid composition may include one or moreflavorants. As used herein, reference to a “flavorant” refers tocompounds or components that can be aerosolized and delivered to a userand which impart a sensory experience in terms of taste and/or aroma.Example flavorants include, but are not limited to, vanillin, ethylvanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry,peach and citrus flavors, including lime and lemon), maple, menthol,mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender,cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hip,yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera,gingko biloba, withania somnifera, cinnamon, sandalwood, jasmine,cascarilla, cocoa, licorice, and flavorings and flavor packages of thetype and character traditionally used for the flavoring of cigarette,cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, alsocan be employed. Example plant-derived compositions that may be suitableare disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No.2012/0152265 both to Dube et al., the disclosures of which areincorporated herein by reference in their entireties. The selection ofsuch further components are variable based upon factors such as thesensory characteristics that are desired for the smoking article, andthe present disclosure is intended to encompass any such furthercomponents that are readily apparent to those skilled in the art oftobacco and tobacco-related or tobacco-derived products. See, e.g.,Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp.(1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products(1972), the disclosures of which are incorporated herein by reference intheir entireties. It should be understood that reference to a flavorantshould not be limited to any single flavorant as described above, andmay, in fact, represent a combination of one or more flavorants.

As shown in the figures, the cartridge 300 of the depictedimplementation also includes a base member 314, which is configured toengage and cover the open distal end of the reservoir cavity 328 of thetank 310. The lower seal 312 of the depicted implementation isconfigured form a substantially air tight and liquid tight seal betweena lower portion of the tank 310 and the bottom cap 326 (see also FIG. 11). In particular, the lower seal 312 is configured to be located withina groove on an outer surface of the base member 314 so as to facilitatea substantially air tight and liquid tight seal between the base member314 and tank 310. In various implementations, the lower seal 312 may bemade of silicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material. In thedepicted implementation, the base member 314 may be made of a moldedpolymer material, such as, for example, a molded plastic material (e.g.,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof), although other materials are possible. The basemember 314 of the depicted implementation also includes a plurality ofslots 335 (see also FIG. 11 ) that are configured to provide liquid flowpassages for the liquid composition contained in the reservoir cavity328 of the tank 310 in order to facilitate transfer of the liquid to theliquid transport element 316. In some implementations, the slots 335 mayalso provide retention of some liquid even when the bulk liquidcomposition in the reservoir cavity 328 is not in contact with the basemember 314 (such as, for example, when the aerosol delivery device 100is upside down).

As shown in the figures, the liquid transport element 316 is disposedwithin the base member 314 and extends between the liquid composition inthe reservoir cavity 328 and the heating member 318 (see also FIG. 11 ).In the depicted implementation, the liquid transport element 316 isformed of a cotton material and, when installed in the cartridge 300,has a curved shape. In other implementations, however, the liquidtransport element 316 may have other shapes and may be formed of avariety of materials configured for transport of a liquid, such as bycapillary action. For example, in some implementations the liquidtransport element may be formed of fibrous materials (e.g., organiccotton, cellulose acetate, regenerated cellulose fabrics, glass fibers),porous ceramics, porous carbon, graphite, porous glass, sintered glassbeads, sintered ceramic beads, capillary tubes, or the like. In otherimplementations, the liquid transport element may be any material thatcontains an open pore network (i.e., a plurality of pores that areinterconnected so that fluid may flow from one pore to another in aplurality of direction through the element). As further discussedherein, some implementations of the present disclosure may particularlyrelate to the use of non-fibrous transport elements. As such, fibroustransport elements may be expressly excluded. Alternatively,combinations of fibrous transport elements and non-fibrous transportelements may be utilized. Representative types of substrates, reservoirsor other components for supporting the aerosol precursor are describedin U.S. Pat. No. 8,528,569 to Newton; U.S. Pat. App. Pub. Nos.2014/0261487 to Chapman et al. and 2014/0059780 to Davis et al.; andU.S. Pat. App. Pub. No. 2015/0216232 to Bless et al.; which areincorporated herein by reference in their entireties. Additionally,various wicking materials, and the configuration and operation of thosewicking materials within certain types of electronic cigarettes, are setforth in U.S. Pat. No. 8,910,640 to Sears et al.; which is incorporatedherein by reference in its entirety. In some implementations, the liquidtransport element may be formed partially or completely from a porousmonolith, such as a porous ceramic, a porous glass, or the like. Examplemonolithic materials suitable for use according to embodiments of thepresent disclosure are described, for example, in U.S. Pat. App. SerialNo. 14/988,109, filed Jan. 5, 2016, and US Pat. No. 2014/0123989 toLaMothe, the disclosures of which are incorporated herein by referencein their entireties.

As shown in the figures, the heating member 318 of the depictedimplementation is also configured to be disposed within the base member314. In particular, the heating member 318 of the depictedimplementation comprises a heating element that has a substantially flatprofile (e.g., initially formed as a substantially planar element).Although other implementations may differ, in the depictedimplementation the heating member 318 includes a first end, a secondend, and a heater loop connecting the first end and the second end. Inparticular, the heater loop of the depicted implementation comprises aserpentine pattern of heater traces that are connected at respectiveends thereof and that extend substantially transverse to a longitudinalaxis of the heating member to connect the first end to the second end.While in some implementations the heater traces may be solid, the heatertraces of the depicted implementation comprise a plurality of splittraces. In the depicted implementation, the edges of the heating memberare substantially solid and the plurality of split traces are located ina central area of the heating member. In such a manner, the heater loopof the depicted implementation may be configured to concentrate heat inan area of the heating element configured to be in contact with theliquid transport element 316.

While in some implementations the heating member may maintain asubstantially flat profile when installed in a cartridge, when theheating member 318 of the depicted implementation is installed in thecartridge 300 it has a curved or bowed shape corresponding to the curvedshape of the liquid transport element 316 (see also FIG. 11 ). In such amanner, the heating member 318 in the installed position contacts abottom surface of the liquid transport element 316. In the depictedimplementation, the curved form of the flat heating member 318 mayprovide a large ratio of cross-sectional flow area to flow path lengththrough the liquid transport element 316. This may provide increasedperformance with respect to delivery of the liquid composition to theliquid transport element 316. When installed, edges of the heatingmember 318 are configured to engage the base member 314 such that theheating member 318 maintains its curved shape. In such a manner, thecurvature of the heating member 318 may also provide a compressive forceagainst the liquid transport element 316. In addition, the springrecover force of the heating member 318 allows the edges of the heatingmember 318 to locate or lock into the base member 314, which may reduceor eliminate any need for additional features configured to hold theheating member 318 in the base member 314 from the other side. Theinstalled curvature of the heating member 318 may also bias deflectionof the heating member 318 that may occur with thermal expansion towardsthe liquid transport element 316, thus helping to maintain thermalcontact between the heating member 318 and the liquid transport element316. In the depicted implementation, the liquid transport element 316and the heating member 318 comprise a heating assembly 334, which,together with the base member 314 and the bottom cap 326, define avaporization chamber 332.

It should be noted that some implementations need not include a heatingassembly, but, rather, may include an atomization assembly configured togenerate an aerosol in another manner. Some examples of atomizationassemblies that generate aerosols in other ways can be found, forexample, in U.S. App. No. 16/544,326, filed on Aug. 19, 2019, and titledDetachable Atomization Assembly for Aerosol Delivery Device, which isincorporated herein by reference in its entirety.

In the depicted implementation, the heating member 318 may be made of ametal material, such as a stainless steel material, including, but notlimited to, 316L, 316, 304, or 304L stainless steel. In otherimplementations, the heating member may be made of a different material,such as, for example, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide(MoSi₂), molybdenum silicide (MoSi), Molybdenum disilicide doped withAluminum (Mo(Si,Al)₂), titanium, platinum, silver, palladium, alloys ofsilver and palladium, graphite and graphite-based materials (e.g.,carbon-based foams and yarns). In further implementations, the heatingmember may be formed from conductive inks, boron doped silica, and/orceramics (e.g., positive or negative temperature coefficient ceramics).Other types of heaters may also be utilized, such as laser diodes ormicroheaters. A laser diode can be configured to deliver electromagneticradiation at a specific wavelength or band of wavelengths that can betuned for vaporization of the aerosol precursor composition and/or tunedfor heating a liquid transport element via which the aerosol precursorcomposition may be provided for vaporization. The laser diode canparticularly be positioned so as to deliver the electromagneticradiation within a chamber, and the chamber may be configured to beradiation-trapping (e.g., a black body or a white body). Suitablemicroheaters are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety. Microheaters,for example, can comprise a substrate (e.g., quartz, silica) with aheater trace thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt,Pt/Ti, boron-doped silicon, or other metals or metal alloys), which maybe printed or otherwise applied to the substrate. A passivating layer(e.g., aluminum oxide or silica) may be provided over the heater trace.Other heaters are described in U.S. Pat. App. Pub. No. 2016/0345633 toDePiano et al., which is incorporated herein by reference in itsentirety.

Although in other implementations additional and/or differing contactfeatures may be provided, the heating member 318 of the depictedimplementation includes a pair of contact holes 331A, 331B that areconfigured to connect the heating member 318 to the heater connectors320A, 320B of the cartridge 300. In depicted implementation, the heaterconnectors 320A, 320B are made of a conductive material and are platedwith nickel and/or gold. Examples of conductive materials include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. In the depicted implementation, the contact holes331A, 331B are configured to have an inner diameter that is less than anouter diameter of the mating portions of the heater connectors 320A,320B. In some implementations, the contact holes may include one or morefeatures (e.g., one or more fingers or extensions) that create aneffective inner diameter that is less than an outer diameter of themating portion of the heater connectors 320A, 320B. In such a manner,the contact holes 331A, 331B of the heating member 318 may create aninterference fit with the upper ends of the heater connectors 320A, 320Bsuch that the heating member 318 may maintain electrical contact withthe heater connectors 320A, 320B. In the depicted implementation, thelower end of the heater connectors 320A, 320B are sealed aroundrespective circumferential surfaces thereof by the pair of O-rings 322A,322B, which are configured to form a substantially air tight and liquidtight seal between the heater connectors 320A, 320B and the bottom cap326. In such a manner, the O-rings 322A, 322B of the depictedimplementation may be made of silicone rubber, boron nitride (BN)rubber, natural rubber, thermoplastic polyurethane, or another resilientmaterial.

The bottom cap 326 of the depicted implementation is configured to besecured to the distal end of the tank 310 via snap features included onone or both of the bottom cap 326 and tank 310; however, otherattachment methods are possible (e.g., via adhesives, heatstaking/welding, ultrasonic welding, etc.). In the depictedimplementation, the bottom cap 326 of the cartridge 300 includes acartridge air inlet channel 330, which is located in an approximatecenter of a bottom surface of the bottom cap 326. Although otherconfigurations are possible, in the depicted implementation thecartridge air inlet channel 330 has a nozzle-like shape. In particular,the cartridge air inlet channel 330 of the depicted implementationincludes a first portion (proximate the bottom surface of the bottom cap326), which has a substantially cylindrical shape and a second portion,which has a substantially conical shape and leads to the vaporizationchamber 332. In such a manner, the internal diameter of the cartridgeair inlet channel 330 decreases before leading to the vaporizationchamber 332. This configuration may help to keep the air inlet channel330 relatively clear of liquid build-up leading into the vaporizationchamber 332.

Although other configurations are possible, the cartridge 300 of thedepicted implementation also includes a pair of metal inserts 324A, 324Bthat are positioned in the bottom cap 326 and are configured to beexposed through the bottom surface thereof. In some implementations, themetal inserts 324A, 324B may be configured for a press or snap fitconnection with the bottom cap 326. In other implementations, the metalinserts may be a product of an insert molding process such that thebottom cap 326 and the metal inserts 324A, 324B form a unitary part. Inthe depicted implementation, the metal inserts 324A, 324B comprise anymaterial configured to be attracted by a magnet, such as variousferromagnetic materials, including, but not limited, to iron, nickel,cobalt, alloys such as steel, and/or any combination thereof.

As noted above, when the cartridge 300 is coupled with the cartridgereceiving chamber 230 of the control device 200, mechanical andelectrical connections are created between the cartridge 300 and thecontrol device 200. In particular, when the cartridge 300 of thedepicted implementation is coupled with the upper frame 206 of thecontrol device 200, a magnetic connection is created between the magnets246A, 246B located in the upper frame 206 and the metal inserts 324A,324B located in the bottom cap 326 of the cartridge 300. In addition,when the cartridge 300 of the depicted implementation is coupled withthe inner frame 206, an electrical connection is created between thepair of conductive pins 236A, 236B of the control device 200 and theheater connectors 320A, 320B of the cartridge 300. Thus, when thecartridge 300 of the depicted implementation is coupled with the controldevice 200, the cartridge 300 is mechanically biased into connectionwith the control device 200 such that electrical connection ismaintained between the cartridge 300 (and, in particular the heatingassembly 334) and the control device (and in particular, the controlcomponent 214 and the battery 216).

When the cartridge 300 of the depicted implementation is coupled withthe control device 200, the electrical connection between the controldevice 200 and the heating member 318 of the cartridge 300 (via theconductive pins 236A, 236B of the control device 200 and the heaterconnectors 320A, 320B of the cartridge) allows the control body 200 todirect electrical current to the heating member 318. In the depictedimplementation, this may occur when a puff on the aerosol deliverydevice 100 is detected (or, in other implementations, via actuation bythe user, such as, for example, via a pushbutton). When a user of theaerosol device 100 of the depicted implementation draws on themouthpiece 302, inlet airflow is directed into the device 100 via a gap400 (see FIG. 11 ) between the cartridge 300 (e.g., an outer wall of thecartridge 300) and the control device 200 (e.g., an inner wall of thecontrol device 200 defining the receiving chamber 230 thereof).

In the depicted implementation, the gap 400 comprises a peripheral gapthat extends around substantially the entire periphery of the cartridge300. It should be understood that in other implementations, the gap neednot extend around the entire periphery of the cartridge, for example insome implementations the gap may comprise one or more gaps that extendaround a portion of the periphery of the cartridge rather than theentire periphery, and in some implementations, the gap may comprise oneor more individual holes. As shown in the figures, the gap 400originates at an interface between an outside surface of the cartridge300 and an inside surface of the control device 200. In particular, thegap 400 originates at the interface of an outer surface of themouthpiece 302 of the cartridge 300 and a top edge of the outer wall 204of the housing 202 of the control device 200. In other implementations,however, the gap may originate at another interface between thecartridge and the control device. For example, in one implementation thegap may originate at an interface between an outside surface of thecartridge below the mouthpiece and inside surface of the control device.Although other implementations may differ, in the depictedimplementation the opening defined by the top edge of the outer wall ofthe housing 202 is greater in size than the outer peripheral surface ofthe mouthpiece 302 such that a maximum perimeter of the cartridge 300 iswholly received within the receiving chamber 230. In addition, as shownin FIG. 11 , when the cartridge 300 of the depicted implementation iscoupled to the control device 200, a portion of the mouthpiece 302extends below the top edge of the outer wall of the housing 202 and intothe receiving chamber 230.

In the depicted implementation, the gap 400 between the cartridge 300and the control device 200 is established and maintained by features ofthe cartridge 300 and the control device 200. Although otherconfigurations are possible, the upper frame 206 of the depictedimplementation includes a plurality of protuberances 260 (see FIG. 6 )that are spaced around an inner surface of the upper frame 206 and thatare configured to laterally position the cartridge 300. In the depictedimplementation, the plurality of protuberances 260 comprise a pluralityof raised elongate bosses that extend from an approximate top of theupper frame 206 to a recessed surface 244 thereof. When the cartridge300 of the depicted implementation is coupled with the control device200, the plurality of protuberances 260 of the upper frame 206 contactan outer surface of the cartridge 300 (and in particular, an outersurface of the mouthpiece 302 and/or an outer surface of the tank 310and/or an outer surface of the bottom cap 326). In such a manner, theprotuberances 260 position the cartridge 300 laterally with respect tothe upper frame 206, thus establishing and maintaining the gap 400. Itshould be understood that in other implementations, the protuberancesmay take other forms (including, for example, one or more bumps), andmay be located on one or more components of the cartridge rather than(or in addition to) the control device.

As a user draws on the device 100, the air that enters the gap 400between the cartridge 300 and the control device 200 travels downwardaround the outside of the cartridge 300 and below the bottom cap 326thereof. In the depicted implementation, inlet air is permitted totravel below the bottom cap 326 due to the vertical position of thecartridge 300 with respect to the bottom of the cartridge receivingchamber 230. In particular, the vertical position of the cartridge 300of the depicted implementation is established using one or more of thelocation features 248A, 248B, 250A, 250B that extend upward from therecessed surface 244 of the upper frame 206, at least one of which isconfigured to contact the bottom surface of the bottom cap 326 when thecartridge 300 is coupled with the control device 200. In such a manner,when the cartridge 300 is received into the control device 200, the gapbetween the cartridge 300 and the control device 200 is also establishedbetween the bottom of the bottom cap 326 and the recessed surface 244 ofthe upper frame 206.

As noted above, although other configurations are possible, the bottomcap 326 of the depicted implementation includes an inlet channel 330that is located in an approximate center of the bottom surface of thebottom cap 326. Because of the gap established between the bottom of thebottom cap 326 and the recessed surface 244 of the upper frame 206,inlet air that travels around the outside of the cartridge 300 and belowthe bottom cap 326 enters the cartridge 300 through the inlet channel330 of the bottom cap 326. The air that enters through the inlet channel330 then enters the vaporization chamber 332 of the cartridge 300 asshown by the beginning of arrowed flow paths shown in FIGS. 11-13 . Asthe air is drawn through the inlet channel 330 into the cartridge 300,the pressure sensor 240 of the control device 200 detects the draw. Inthe depicted implementation, the pressure sensor 240 may detect a drawby sensing a pressure drop in the cartridge 300. A pressure drop in thecartridge 300 of the depicted implementation is conveyed to the pressuresensor 240 via a single offset pressure channel 342 that is defined inthe bottom cap 326 of the cartridge 300. The pair of upper frame sealtubes 209A, 209B of the upper frame seal 208 of the control device 200are configured such that regardless of the rotational orientation of aninstalled cartridge 300, when the cartridge 300 is coupled with thecontrol device 200, one of the seal tube channels 211A, 211B of theupper frame seal tubes 209A, 209B will substantially align with theoffset pressure channel 342 of the cartridge 300, as shown in FIG. 11 .In the depicted implementation, the cavity defined by the pressuresensor seal 210 and the bottom of the upper frame seal 208 (with whichthe pressure channel 342 communicates when the cartridge 300 is coupledwith the control device) represents a substantially sealed cavity.During a draw on the device 100 of the depicted implementation there issubstantially little to no air flow through the pressure channel 342,and thus the pressure channel 342 acts as a static pressure line,thereby not substantially affecting the system pressure drop.

When a draw is detected by the pressure sensor 240, the controlcomponent 214 directs current through the heating member 318 in order toheat the heating member 318. As the heating member 318 heats, at least aportion of the liquid composition contained in the liquid transportelement 316 is vaporized in the vaporization chamber 332. Accordingly,aerosol produced in the vaporization chamber 332 may then directed tothe user. In particular, as the air enters the cartridge 300 via the airinlet channel 330, the air travels through the vaporization chamber 332where it impinges on the heating member 318 substantiallyperpendicularly thereto and mixes with the vaporized liquid compositionto become the aerosol. Due to the geometry of the vaporization chamber332 and the bottom cap 326, the aerosol is split into two separate pathsthat extend through the inside of the bottom cap 326 and then throughthe aerosol flow tubes 333A, 333B that are defined on opposite sides ofthe reservoir cavity 328 of the tank 310 (see FIGS. 12B and 13 ). Thisrelatively tortuous configuration may increase the effective flow pathlength and area for heat sinking, thus providing increased cooling ofthe aerosol stream prior to reaching the user. As shown in the figures,the two aerosol paths converge at the proximal end of the tank 310 andbelow the upper aerosol channel insert 306. The recombined aerosol thenflows through the upper aerosol channel insert 306 and out of the exitportal 315 of the mouthpiece 300, to the user. It should be understoodthat the aerosol passages downstream from the air inlet channel 330inlet are configured to be oversized, in order to minimize anyadditional system pressure drop created by these passages. In thismanner, the device is configured such that the greatest portion of thesystem pressure drop is present in the location of the pressure channel342, to maximize the pressure “signal” available to the pressure sensor240.

Although other configurations are possible, in the depictedimplementation, the upper aerosol channel insert 306 is configured toabsorb liquid formed by deposition and/or condensation from aerosolformed in the vaporization chamber 332, and is configured to have rigidor semi-rigid properties. As such, the upper aerosol channel insert 306of the depicted implementation may be made of a fibrous, sinteredbeaded, or open cell foam material. In such a manner, the upper aerosolchannel insert 306 may be configured for a press or snap fit attachmentwith the mouthpiece 302. The upper aerosol channel insert 306 is alsoconfigured to help to prevent accumulation of liquid from exiting thecartridge 300 through the mouthpiece 302. In addition, the upper aerosolchannel insert 306 is located in such a way that aerosol produced in thevaporization chamber 332 passes through the insert 306 just prior toexiting the cartridge 300. In the depicted implementation, the insidecavity of the upper aerosol channel insert 306 may also serve as acooling chamber within which the formed aerosol can be allowed to expandand/or cool before passing through the exit portal 315. In someimplementations, the vaporization chamber 332 and the cooling chambermay be configured to have a defined relative volume ratio.

FIG. 14 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to another example implementationof the present disclosure. As shown in the figure, the control device400 of the depicted implementation generally includes a housing 402defining an outer wall 404, an upper frame 406, a pressure sensor seal410, a lower frame 412, a control component 414, a battery 416, avibration motor 418, a motor housing 420, a pin seal 422, an end cap424, a light diffuser 426 (shown assembled to the end cap 424), and avent 439. The control device 400 of the depicted implementation alsoincludes a front foam pad 431, a back foam pad 433, an upper chassisseal 435, and a base seal 437. In the depicted implementation, the frontfoam pad is configured to be disposed between the battery 416 and thecontrol component 414, and the back foam pad 433 is configured to bedisposed between the battery 416 and the lower frame 412. The upperchassis seal 435 is configured to seal around the upper frame 406, andthe base seal 437 is configured to seal around the end cap 424. Thearrangement of the components of the control device 400 is illustratedin FIG. 15 . In particular, FIG. 15 illustrates a front section view ofthe control device 400. As illustrated in the figure, the upper frame406 of the control device 400 defines a cartridge receiving chamber 430within which a cartridge may be coupled. The control device 400 alsoincludes a pair of opposite indication windows 432 that are definedthrough the outer wall 404 of the housing 402, as well as through theupper frame 406. As will be described in more detail below, in variousimplementations the indication windows 432 may provide a user with theability to view one or more components (and/or conditions thereof) of aninstalled cartridge. It will be appreciated, however, that theillustrated indication windows 432 are provided by way of example andnot by way of limitation. For example, alternative implementations mayinclude an indication window 432 having a different shape than thatillustrated. As another example, some implementations may include only asingle indication window 432 or may omit the indication windows 432altogether. In the depicted implementation, the upper frame 406 and thehousing 402 represent different parts; however, in otherimplementations, the upper frame and the housing may be continuouslyformed such that they comprise the same part.

In the depicted implementation, the housing 402 comprises a metalmaterial, such as, for example, aluminum; however, in otherimplementations the housing may comprise a metal alloy material, and instill other implementations the housing may comprise a molded polymermaterial. In the depicted implementation, one or more of the upper frame406, lower frame 412, and end cap 424 may be made of a molded polymermaterial, such as, for example, a molded plastic material (e.g.,polybutylene terephthalate (PBT), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof). In other implementations, oneor more of these components may be made of other materials, including,for example, metal materials (e.g., aluminum, stainless steel, metalalloys, etc.), glass materials, ceramic materials (e.g., alumina,silica, mullite, silicon carbide, silicon nitride, aluminum nitride,etc.), composite materials, and/or any combinations thereof.

In the depicted implementation, the lower frame 412 is configured tocontain the battery 416 in an interior area thereof. In the depictedimplementation, the battery may comprise a lithium polymer (LiPo)battery; however various other batteries may be suitable. Some otherexamples of batteries that can be used according to the disclosure aredescribed in U.S. Pat. App. Pub. No. 2010/0028766 to Peckerar et al.,the disclosure of which is incorporated herein by reference in itsentirety. In some implementations, other types of power sources may beutilized. For example, in various implementations a power source maycomprise a replaceable battery or a rechargeable battery, solid-statebattery, thin-film solid-state battery, rechargeable supercapacitor orthe like, and thus may be combined with any type of rechargingtechnology, including connection to a wall charger, connection to a carcharger (e.g., cigarette lighter receptacle, USB port, etc.), connectionto a computer, such as through a universal serial bus (USB) cable orconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a USBconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C as may be implemented ina wall outlet, electronic device, vehicle, etc.), connection to aphotovoltaic cell (sometimes referred to as a solar cell) or solar panelof solar cells, a wireless charger, such as a charger that usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)), or a wireless radio frequency (RF) based charger, andconnection to an array of external cell(s) such as a power bank tocharge a device via a USB connector or a wireless charger. An example ofan inductive wireless charging system is described in U.S. Pat. App.Pub. No. 2017/0112196 to Sur et al., which is incorporated herein byreference in its entirety. In further implementations, a power sourcemay also comprise a capacitor. Capacitors are capable of dischargingmore quickly than batteries and can be charged between puffs, allowingthe battery to discharge into the capacitor at a lower rate than if itwere used to power the heating member directly. For example, asupercapacitor - e.g., an electric double-layer capacitor (EDLC) - maybe used separate from or in combination with a battery. When used alone,the supercapacitor may be recharged before each use of the article.Thus, the device may also include a charger component that can beattached to the smoking article between uses to replenish thesupercapacitor. Examples of power supplies that include supercapacitorsare described in U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,which is incorporated herein by reference in its entirety.

The aerosol delivery device 400 of the depicted implementation includesa control mechanism in the form of the control component 414, which isconfigured, in part, to control the amount of electric power provided tothe heating member of the cartridge. Although other configurations arepossible, the control component 414 of the depicted implementationcomprises a circuit board 434 (e.g., a printed circuit board (PCB)) thatincludes both rigid and flexible portions. In particular, the circuitboard 434 of the depicted implementation includes a rigid centralsection 415 and two rigid end sections comprising a proximal end section417 and a distal end section 419, with each of the end sections 417, 419being connected to the central section 415 by a respective flexibleconnection. In such a manner, when the lower frame 412, battery 416, andcircuit board 434 are assembled into the control device 400, the centralsection 415 of the circuit board 434 is configured to be disposedproximate a major surface of the battery 416, and the two end sections417, 419 are configured to be disposed substantially perpendicular tothe central section 415. In particular, the proximal end section 417 ofthe circuit board 434 is configured to extend over the top of the lowerframe 412, and the distal end section 419 is configured to extend overthe bottom of the lower frame 412. The lower frame 412 of the controldevice 400 is also configured to contain the motor housing 420, intowhich the vibration motor 418 is received. In various implementations,the vibration motor 418 may provide haptic feedback relating to variousoperations of the device.

The central section 415 of the depicted implementation also includes anindicator in the form of a light source 421. In some implementations,the light source may comprise, for example, at least one light emittingdiode (LED) capable of providing one or more colors of light. In otherimplementations, the light source may be configured to illuminate inonly one color, while in other implementations, the light source may beconfigured to illuminate in variety of different colors. In still otherimplementations, the light source may be configured to provide whitelight. In the depicted implementation, the light source 421 comprises anRGB (red, green, blue) LED that is configured to provide a variety ofcolors of light, including white light. The central section 415 of thedepicted circuit board 434 also includes electrical contacts 423 thatare configured to operatively connect the circuit board 434 to thevibration motor 418. Other types of electronic components, structuresand configurations thereof, features thereof, and general methods ofoperation thereof, are described in U.S. Pat. Nos. 4,735,217 to Gerth etal.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.;6,040,560 to Fleischhauer et al.; 7,040,314 to Nguyen et al. and8,205,622 to Pan; U.S. Pat. App. Pub. Nos. 2009/0230117 to Fernando etal., 2014/0060554 to Collet et al., and 2014/0270727 to Ampolini et al.;and U.S. Pat. App. Pub. No. 2015/0257445 to Henry et al.; which areincorporated herein by reference. Yet other features, controls orcomponents that can be incorporated into aerosol delivery devices of thepresent disclosure are described in U.S. Pat. Nos. 5,967,148 to Harriset al.; 5,934,289 to Watkins et al.; U.S. Pat. No. 5,954,979 to Countset al.; 6,040,560 to Fleischhauer et al.; 8,365,742 to Hon; 8,402,976 toFernando et al.; U.S. Pat. App. Pub. Nos. 2010/0163063 to Fernando etal.; 2013/0192623 to Tucker et al.; 2013/0298905 to Leven et al.;2013/0180553 to Kim et al., 2014/0000638 to Sebastian et al.,2014/0261495 to Novak et al., and 2014/0261408 to DePiano et al.; whichare incorporated herein by reference in their entireties.

In the depicted implementation, the vent 439 is configured to beinstalled on the inside of the housing 402 such that it covers theaperture 425. As such, in the depicted implementation one side of thevent 439 may include a pressure sensitive adhesive. In the depictedimplementation, the vent 439 comprises a breathable membrane material,such as, for example, a Gore-Tex® material; however, other suitablematerials are possible. In the depicted implementation, the light source421 is covered by the light diffuser 426, a portion of which isconfigured to be received by the end cap 424. In such a manner, whenassembled, the light diffuser 426 is positioned in or proximate anaperture 425 defined in the outer wall 404 of the housing 402 andproximate a distal end thereof. In the depicted implementation, theaperture 425 comprises a narrow, elongate opening; however, in otherimplementations, the aperture may be provided in any desired shape andmay be positioned at any location on the control device 400. In someimplementations, the light diffuser 426 may comprise a transparent ortranslucent member configured to allow a user to view the light source421 from the outside of the housing 402. In the depicted implementation,the light diffuser 426 may be made of a molded polymer material, suchas, for example, a molded plastic material (e.g., polybutyleneterephthalate (PBT), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof), although other materials,including glass, are possible. In various implementations, furtherindicators (e.g., other haptic feedback components, an audio feedbackcomponent, or the like) can be included in addition to or as analternative to the indicators included in the depicted implementation.Additional representative types of components that yield visual cues orindicators, such as LED components, and the configurations and usesthereof, are described in U.S. Pat. Nos. 5,154,192 to Sprinkel et al.;8,499,766 to Newton and 8,539,959 to Scatterday; U.S. Pat. App. Pub. No.2015/0020825 to Galloway et al.; and U.S. Pat. App. Pub. No.2015/0216233 to Sears et al.; which are incorporated herein by referencein their entireties.

Although other configurations are possible, the proximal end section 417of the circuit board 434 of the depicted implementation includes a pairof conductive pins 436A, 436B, as well as a pressure sensor 440. In thedepicted implementation, the conductive pins 436A, 436B comprisespring-loaded pins (e.g., electrical pogo pins) that extend through theupper frame 406 such that portions of the ends of the pins 436A, 436Bextend into the cartridge receiving chamber 430 and are biased in thatposition due to the force of the internal springs of the conductive pins436A, 436B. In such a manner, when a cartridge is coupled with thecontrol device 400, the conductive pins 436A, 436B are configured tocontact corresponding features of the cartridge and deflect downward(e.g., toward the lower frame 412) against the force of the springs,thus operatively connecting the installed cartridge with the controlcomponent 414 and the battery 416. In the depicted implementation, theconductive pins 436A, 436B comprise gold plated metal pins; however,other materials or combinations of materials, which may also includecoatings and/or platings of electrically conductive materials, arepossible. Examples of electrically conductive materials, include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. Although other profiles are possible, the ends ofthe conductive pins 436A, 436B of the depicted implementation have arounded profile such that deflection of the conductive pins 436A, 436Bis facilitated when a cartridge is inserted into the cartridge receivingchamber 430. In other implementations, the conductive pins may bepositioned in other locations of the cartridge receiving chamber 430,such as, for example, proximate the top of the cartridge receivingchamber 430. In other implementations, the conductive pins may bepositioned at a point on the sides of the upper frame 406 between theproximal end of the outer housing 402 and the bottom wall of the upperframe 406. Further, in still other implementations the conductive pinsmay be positioned between a midpoint of the sidewalls and the proximalend of the outer housing 402 (i.e., in an upper half of the sidewalls).Alternatively, the conductive pins may be positioned between a midpointof the sidewalls and the bottom wall of the inner frame wall (e.g., in alower half of the sidewalls). Moreover, in still other implementations,the conductive pins may be present at any position of the upper frame406.

In various implementations, the aerosol delivery device may include anairflow sensor, pressure sensor, or the like. As noted above, thecontrol component 414 of the depicted implementation includes a pressuresensor 440, which is positioned proximate and below the cartridgereceiving chamber 430. The position and function of the pressure sensor440 of the depicted implementation will be described below; however, inother implementations an airflow or pressure sensor may be positionedanywhere within the control device 400 so as to subject to airflowand/or a pressure change that can signal a draw on the device and thuscause the battery 416 to delivery power to the heating member of acartridge. Various configurations of a printed circuit board and apressure sensor, for example, are described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., the disclosure of which is incorporatedherein by reference in its entirety. In the absence of an airflowsensor, pressure sensor, or the like, an aerosol delivery device may beactivated manually, such as via a pushbutton that may be located on thecontrol device and/or the cartridge. For example, one or morepushbuttons may be used as described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., which is incorporated herein by referencein its entirety. Likewise, a touchscreen may be used as described inU.S. Pat. App. Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference in its entirety. As afurther example, components adapted for gesture recognition based onspecified movements of the aerosol delivery device may be used as aninput. See U.S. Pat. App. Pub. 2016/0158782 to Henry et al., which isincorporated herein by reference in its entirety.

Although not included in the depicted implementation, someimplementations may include other types of input elements, which mayreplace or supplement an airflow or pressure sensor. The input may beincluded to allow a user to control functions of the device and/or foroutput of information to a user. Any component or combination ofcomponents may be utilized as an input for controlling the function ofthe device. In some implementations, an input may comprise a computer orcomputing device, such as a smartphone or tablet. In particular, theaerosol delivery device may be wired to the computer or other device,such as via use of a USB cord or similar protocol. The aerosol deliverydevice may also communicate with a computer or other device acting as aninput via wireless communication. See, for example, the systems andmethods for controlling a device via a read request as described in U.S.Pat. App. Pub. No. 2016/0007561 to Ampolini et al., the disclosure ofwhich is incorporated herein by reference in its entirety. In suchembodiments, an APP or other computer program may be used in connectionwith a computer or other computing device to input control instructionsto the aerosol delivery device, such control instructions including, forexample, the ability to form an aerosol of specific composition bychoosing the nicotine content and/or content of further flavors to beincluded. Additional representative types of sensing or detectionmechanisms, structure and configuration thereof, components thereof, andgeneral methods of operation thereof, are described in U.S. Pat. Nos.5,261,424 to Sprinkel, Jr.; 5,372,148 to McCafferty et al.; and PCT WO2010/003480 to Flick; which are incorporated herein by reference intheir entireties.

In the depicted implementation, the pressure sensor seal 410 isconfigured to cover the pressure sensor 440 to protect it from anyliquid and/or aerosol from an installed cartridge. In such a manner, thepressure sensor seal 410 of the depicted implementation (as well asother sealing members, including the upper chassis seal 435, lowerchassis seal 437, motor housing 420, and the pin seal 422) may be madeof silicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material.

Although other configurations are possible, the distal end section 419of the circuit board 434 includes the external connection element 438.In various implementations, the external connection element 438 may beconfigured for connecting to an external connector and/or a dockingstation or other power or data source. For example, in someimplementations an external connector may comprise first and secondconnector ends that may be interconnected by a union, which may be, forexample, a cord of variable length. In some implementations, the firstconnector end may be configured for electrical and, optionally,mechanical connection with the device, and the second connector end maybe configured for connection to a computer or similar electronic deviceor for connection to a power source. An adaptor including a USBconnector at one end and a power unit connector at an opposing end isdisclosed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference in its entirety. In the depictedimplementation, the pin seal 422 is configured to seal the interfacebetween the external connection element 438 and the end cap 424. In thedepicted implementation, one or more pins of the external connectionelement 438 may extend through the end cap 424 of the control device asnoted above. In the depicted implementation, the end cap 424 alsoincludes a pair of end cap pins 441A, 441B that may be affixed to theend cap 424. For example, in some implementations, the end cap pins441A, 441B may be insert-molded into the end cap 424. In someimplementations, a bottom surface of the end cap pins 441A, 441B (which,in some implementations, may be flat) may be configured to provideattraction for magnets contained in an external charger assembly. Insuch a manner, the end cap pins 441A, 441B may be made of any materialconfigured to be attracted by a magnet, such as various ferromagneticmaterials, including, but not limited, to steel, iron, nickel, cobalt,other alloys, and/or any combination thereof. A detailed view of the endcap assembly is shown in FIG. 16 .

Referring back to FIG. 15 , the upper frame 406 includes a pair ofmagnets 446A, 446B that are exposed in the cartridge receiving chamber430. In various implementations, the magnets 446A, 446B may comprise anytype of magnets, including rare earth magnets. For example, in someimplementations, one or more of the magnets may comprise Neodymiummagnets (also known as NdFeB, NIB, or Neo magnets). In variousimplementations, different grades of Neodymium magnets may be used,including, for example, N35, N38, N40, N42, N45, N48, N50, and/or N52grades. In other implementations, one or more of the magnets maycomprise Samarium Cobalt magnets (also known as SmCo magnets). In stillother implementations, one or more of the magnets may compriseCeramic/Ferrite magnets. In other implementations, one or more of themagnets may comprise Aluminum-Nickel-Cobalt (AlNiCo) magnets. In any ofthe foregoing implementations, one or more of the magnets may be platedand/or coated. For example, in some implementations, one or more of themagnets may be coated with nickel. In other implementations, one or moremagnets may be coated with one or more of zinc, tin, copper, epoxy,silver and/or gold. In some implementations, one or more of the magnetsmay be coated with combinations of these materials. For example, in oneimplementation, one or more of the magnets may be coated with nickel,copper, and nickel again. In another implementation, one or more of themagnets may be coated with nickel, copper, nickel, and a top coating ofgold.

FIG. 16 illustrates a perspective view of an end cap assembly, accordingto an example implementation of the present disclosure. In particular,FIG. 16 illustrates a perspective view of the end cap 424, lightdiffuser 426, and end cap pins 441A, 441B. As shown in the figure, theend cap 424 also includes a seal groove 442, which extends around adistal periphery of the end cap 424. Referring back to FIG. 15 , theseal groove 442 of the end cap 424 is configured to receive an end capseal 443 that provides a sealing interface between the end cap 424 andthe housing 402, and in particular, an inner surface of the outer wall404. In various implementations, the end cap seal 443 may be made ofsilicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material. As also shownin FIG. 15 , in various implementations the upper portions of the endcap pins 441A, 441B are configured to engage with the lower frame 412.For example, in the depicted implementation the upper portions of theend cap pins 441A, 441B are configured to create an interference orpress-fit engagement with corresponding slotted openings in the lowerframe 412. In various implementations, the interface between the end cap424 and the housing 402 (e.g., via the interface between the end capseal 443 and the inner surface of the outer housing wall 404 and/or theupper portions of the end cap pins 441A, 441B and the lower frame 412)may create a press-fit engagement with the housing 402 that isconfigured to be releasable so that the end cap 424 (or end capassembly) may be removable.

In various implementations, the control device may include one or morecomponents configured to meet battery outgassing requirements under UL8139. For example, the control device may include an end cap configuredto eject in the event that sudden pressurization occurs within thecontrol device enclosure. In one implementation, the end cap may includeretaining pins that extend substantially perpendicularly from a wall ofthe end cap. The retaining pins may be configured to mate with receivingfeatures (e.g., holes) in a frame of the control device to establish afriction fit or press fit that may be overcome if an internal pressurewithin the control device housing exceeds a defined internal pressure.

FIGS. 17A - 17C illustrate several subassemblies that together comprisethe control device 400. In particular, FIG. 17A illustrates a lowerinner subassembly 447 and an upper inner subassembly 445, FIG. 17Billustrates an inner subassembly 451 and a housing subassembly 449, andFIG. 17C illustrates a main subassembly 453 and an end cap subassembly455. In the depicted implementation, the upper inner subassembly 445 isassembled by applying glue to receiving pockets of the upper frame 406and press-fitting the magnets 446A, 446B into the upper frame 406. Inaddition, the sensor seal 410 is pressed into a receiving pocket of theupper frame 406, and the upper chassis seal 435 is stretched over areceiving groove of the upper frame 406. In the depicted implementation,the lower inner subassembly 447 is assembled by soldering the battery416 to the circuit board 434 (in the depicted implementation, thevibration motor 418 is pre-soldered to the circuit board 434). Thecircuit board 434 is then coupled with the battery 416 using the frontfoam pad 431, which may have adhesive material on both sides thereof.The motor housing 420 may then be pressed onto the vibration motor 418,such as via an interference fit. The circuit board 434 with the attachedcomponents may then be inserted into the lower frame 412, with the backfoam pad 433 located in between (adhesive may be present on one or bothsides of the back foam pad 433 to aid in assembly). As illustrated inFIG. 17A, the lower inner subassembly 447 and the upper innersubassembly 445 may then be assembled together via one or more snapfeatures that may be included on the upper inner subassembly 445 and/orthe lower inner subassembly 447. As illustrated in FIG. 17B, the innersubassembly 451, comprised of the lower inner subassembly 447 and theupper inner subassembly 445, may then be inserted into the housingsubassembly 449, which is assembled by adhering the vent 439 on theinside of the housing 406 proximate the aperture 425 thereof. In someimplementations, adhesive may be used to secure the parts together (suchas, for example, by applying adhesive through one or more holes in thelower frame 412).

FIGS. 18 - 20 illustrate a cartridge 500, a portion which is configuredto be coupled with the cartridge receiving chamber 430 of the innerframe 406 of the control device 400 such that mechanical and electricalconnections are created between the cartridge 400 and the control device400. In particular, when the cartridge 400 of the depictedimplementation is coupled with the upper frame 406 of the control device400, a magnetic connection is created between the magnets 446A, 446Blocated in the upper frame 406 and corresponding features of thecartridge 500. In addition, when the cartridge 500 of the depictedimplementation is coupled with the inner frame 406, an electricalconnection is created between the pair conductive pins 436A, 436B of thecontrol device 400 and corresponding features of the cartridge 500. Assuch, when the cartridge 500 is received in the upper frame 430 of thecontrol device 400, the cartridge 500 may be operatively connected tothe control component 414 and the battery 416 of the control device 400.Thus, when the cartridge 500 of the depicted implementation is coupledwith the control device 400, the cartridge 500 is mechanically biasedinto connection with the control device 400 such that electricalconnection is maintained between the cartridge and the control device.

In particular, FIG. 18 illustrates a perspective view of a cartridge500, according to another example implementation of the presentdisclosure, FIG. 19 illustrates an exploded perspective view of thecartridge 500, and FIG. 20 illustrates a side section view of thecartridge 500. Although other configurations are possible, the cartridge500 of the depicted implementation generally includes a mouthpiece 502,a mouthpiece insert 504, an upper aerosol channel insert 506, an uppercartridge seal 508, a tank 510 that defines a tank wall 511, a lowercartridge seal 512, a base member 514, a liquid transport element (e.g.,a wick) 516, a heating member 518, a pair of heater connectors 520A,520B, a pair of metal inserts 524A, 524B, and a bottom cap 526.

As shown in the figures, the mouthpiece 502 of the depictedimplementation defines a proximal end and a distal end, with theproximal end of the mouthpiece 502 defining an exit portal 515 therein.In the depicted implementation, the mouthpiece insert 504 is configuredto be located proximate the proximal end of the mouthpiece 502 such thatit extends through the exit portal 515 thereof. In the depictedimplementation, the mouthpiece 502 and the mouthpiece insert 504 may bemade of a molded polymer material, such as, for example, a moldedplastic material (e.g., polypropylene, acrylonitrile butadiene styrene(ABS), polyethylene, polycarbonate, Polyamide (Nylon), high impactpolystyrene, and combinations thereof), although other materials arepossible. The mouthpiece insert 504 of the depicted implementationincludes a flange feature on a lower portion thereof such that themouthpiece insert 504 may be installed from inside the mouthpiece 502and may be configured for a press or snap-fit connection with the exitportal 515. In other implementations, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.). In still other implementations, the mouthpiece and mouthpieceinsert may be constructed using an insert molding or overmolding processsuch that the mouthpiece 502 and the mouthpiece insert 504 comprise aunitary part. The mouthpiece 502 of the depicted implementation isconfigured to be secured to the tank 510 via snap features. For example,the mouthpiece 502 of the depicted implementation includes a ridgefeature 543 (see FIG. 20 ) that extends around at least a portion of aninner surface thereof, and the tank 510 includes a corresponding groovefeature 541 that extends around at least a portion of an outer surfacethereof. In other implementations, these features may be reversed (e.g.,the mouthpiece may include a groove and the tank may include a ridgefeature). In still other implementations, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.).

In some implementations, the mouthpiece insert may exhibit a colorassociated with a distinctive characteristic of the cartridge. Forexample, in some implementations a cartridge of the present disclosuremay include a liquid composition that includes a distinctivecharacteristic such as, for example, a particular flavorant (asdiscussed infra), or a specific strength of nicotine, although anycharacteristic of the cartridge may be considered a distinctivecharacteristic. For the purposes of the current description, the term“color” should be interpreted broadly, for example covering any color orany shade of the same color. It should also be noted that in someimplementations, certain colors may be commonly associated withparticular distinctive characteristics (e.g., the color green may beassociated with a mint flavorant, and the color red may be associatedwith an apple flavorant); however, in other implementations, certaincolors may be associated with particular distinctive characteristicsaccording to an index or guide, which may be provided or made availableto a user. Examples of distinctive characteristics are described in U.S.Pat. App. Serial No. 16/171,920, titled Aerosol Delivery Device withFlavor Indicator, which is incorporated herein by reference in itsentirety.

The tank 510 of the depicted implementation defines a proximal end and adistal end, wherein the mouthpiece 502 is configured to engage theproximal end of the tank 510 and the bottom cap 526 is configured toengage the distal end of the tank 510. In the depicted implementation,the tank 510 also defines a reservoir cavity 528 that includes a closedproximal end and an open distal end. As such, the reservoir cavity 528of the tank 510 is configured to contain a liquid composition (e.g., ane-liquid or aerosol precursor composition) therein. The closed proximalend of the reservoir cavity 528 allows the cavity to create a reliableseal on the top side of the liquid composition column. This may preventthe seepage/entry of air into the reservoir cavity from the top end whenthe cartridge is held upright. This may also prevent air from enteringfrom the top of the liquid composition column, which may create a vacuumand may reduce the potential of the liquid composition to leak from thebottom of the tank through the liquid transport element or otherpassages.

Although other configurations are possible, in the depictedimplementation a pair of internal aerosol flow tubes are defined onopposite sides of the reservoir cavity 528 of the tank 510. In the caseof an injection molded tank 510, the internal aerosol flow tubes areconfigured to be molded therein. As will be described in more detailbelow, aerosol produced in a vaporization chamber of the cartridge 500is configured to travel through the aerosol flow tubes for delivery to auser.

In the depicted implementation, the tank wall 511 is configured to betransparent or translucent so that the liquid composition containedtherein may be visible externally. As such, in the depictedimplementation the entire tank wall 511 is configured to be transparentor translucent. Alternatively, in some implementations, only a portionof the tank wall or only a single side of the tank wall may betransparent or translucent while the remaining portions of the tank wallmay be substantially opaque. In other implementations, the tank wall maybe substantially opaque, and a strip extending from the proximal end ofthe tank to the distal end of the tank may be transparent ortranslucent. In further implementations, the tank wall may be colored.In some implementations, the color can be configured so that the liquidcomposition within the tank is still visible, such by using atransparent or translucent outer tank wall. In other implementations,the tank wall can be configured so that the outer tank wall hassubstantially opaque color. In the depicted implementation, the tank 510may be made of a molded polymer material, such as, for example, a moldedplastic material (e.g., a copolyester material, such as, for example,Tritan™ copolyester), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof), although other materials,including glass, are possible.

In some implementations, the indication window 432 of the control device400 may be configured so that at least a portion of the tank 510 and atleast a portion of the bottom cap 526 are visible when the cartridge 500is engaged with the control device 400. As noted above, in someimplementations at least a portion of the tank wall 511 may beconfigured to be at least partially transparent or translucent so thatthe liquid composition contained therein is visible externally. Thus,the relative amount of any liquid composition present in the tank 510may be visible through the indication window when the cartridge 500 isengaged with the control device 400. As illustrated in FIGS. 14 and 15 ,the indication window 432 of the depicted implementation is located nearthe proximal end of the control device 400 and is configured as anelongate oval shaped cut-out in the outer wall 404 of the housing 402and the upper frame 406 of the control device 400. It should beunderstood that in other implementations, the indication window my haveany other shapes and/or locations. For example, in some implementationsthe indication window may be configured as a notch extending from theproximal end of the outer wall of the control device a distance towardthe distal end of the device. In still other implementations, theindication window may be configured so as not to have any open bordersand thus may expressly exclude a notch configuration as noted above. Insome implementations, the indication window may be completely open, andin other implementations, the indication window may have a transparentmember (e.g., glass or plastic) positioned in the opening defined by theindication window or covering the indication window on one or both ofthe inner surface and outer surface of the outer wall of the controldevice. It should be understood that in some implementations, theindication window may be formed in part by the cartridge and in part bythe control device. For example, in some implementations, the cartridgemay include a portion of the indication window (e.g., a top portion ofan indication window), and the control device may include a separateportion of the indication window (e.g., a bottom portion of theindication window). In some implementations, the indication window maybe located in the cartridge rather than, or in addition to, anindication window located in the control device. For example, in oneimplementation the mouthpiece and/or another cartridge component may actas a sleeve covering a transparent wall of the cartridge. The sleeve mayinclude an indication window, which may be positioned mostly or entirelyabove a power unit chamber when the cartridge is inserted into thecontrol device. As noted, other implementations may not include anyindication windows.

Although other configurations are possible, in the depictedimplementation the proximal end of the tank 510 is configured to receivethe upper cartridge seal 508, which is configured to form asubstantially air tight and liquid tight seal between the tank 510 andthe mouthpiece 502. As such, the upper cartridge seal 508 may be made ofsilicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material. In thedepicted implementation, the upper cartridge seal 508 is also configuredto receive and seal the upper aerosol channel insert 506 (see also FIG.20 ).

For aerosol delivery systems that are characterized as electroniccigarettes, the aerosol precursor composition may incorporate tobacco orcomponents derived from tobacco. In one regard, the tobacco may beprovided as parts or pieces of tobacco, such as finely ground, milled orpowdered tobacco lamina. Tobacco beads, pellets, or other solid formsmay be included, such as described in U.S. Pat. App. Pub. No.2015/0335070 to Sears et al., the disclosure of which is incorporatedherein by reference. In another regard, the tobacco may be provided inthe form of an extract, such as a spray dried extract that incorporatesmany of the water soluble components of tobacco. Alternatively, tobaccoextracts may have the form of relatively high nicotine content extracts,which extracts also incorporate minor amounts of other extractedcomponents derived from tobacco. In another regard, components derivedfrom tobacco may be provided in a relatively pure form, such as certainflavoring agents that are derived from tobacco. In one regard, acomponent that is derived from tobacco, and that may be employed in ahighly purified or essentially pure form, is nicotine (e.g.,pharmaceutical grade nicotine).

In the depicted implementation, the liquid composition, sometimereferred to as an aerosol precursor composition or a vapor precursorcomposition or “e-liquid”, may comprise a variety of componentsincluding, by way of example, a polyhydric alcohol (e.g., glycerin,propylene glycol, or a mixture thereof), nicotine, tobacco, tobaccoextract, and/or flavorants. Representative types of aerosol precursorcomponents and formulations also are set forth and characterized in U.S.Pat. No. 7,217,320 to Robinson et al. and U.S. Pat. App. Pub. Nos.2013/0008457 to Zheng et al.; 2013/0213417 to Chong et al.; 2014/0060554to Collett et al.; 2015/0020823 to Lipowicz et al.; and 2015/0020830 toKoller, as well as WO 2014/182736 to Bowen et al., the disclosures ofwhich are incorporated herein by reference in their entireties. Otheraerosol precursors that may be employed include the aerosol precursorsthat have been incorporated in VUSE® products by R. J. Reynolds VaporCompany, the BLU™ products by Fontem Ventures B.V., the MISTIC MENTHOLproduct by Mistic Ecigs, MARK TEN products by Nu Mark LLC, the JUULproduct by Juul Labs, Inc., and VYPE products by CN Creative Ltd. Alsodesirable are the so-called “smoke juices” for electronic cigarettesthat have been available from Johnson Creek Enterprises LLC. Stillfurther example aerosol precursor compositions are sold under the brandnames BLACK NOTE, COSMIC FOG, THE MILKMAN E-LIQUID, FIVE PAWNS, THEVAPOR CHEF, VAPE WILD, BOOSTED, THE STEAM FACTORY, MECH SAUCE, CASEYJONES MAINLINE RESERVE, MITTEN VAPORS, DR. CRIMMY’S V-LIQUID, SMILEY ELIQUID, BEANTOWN VAPOR, CUTTWOOD, CYCLOPS VAPOR, SICBOY, GOOD LIFEVAPOR, TELEOS, PINUP VAPORS, SPACE JAM, MT. BAKER VAPOR, and JIMMY THEJUICE MAN.

The amount of aerosol precursor that is incorporated within the aerosoldelivery system is such that the aerosol generating piece providesacceptable sensory and desirable performance characteristics. Forexample, it is highly preferred that sufficient amounts of aerosolforming material (e.g., glycerin and/or propylene glycol), be employedin order to provide for the generation of a visible mainstream aerosolthat in many regards resembles the appearance of tobacco smoke. Theamount of aerosol precursor within the aerosol generating system may bedependent upon factors such as the number of puffs desired per aerosolgenerating piece. In the depicted implementation, the reservoir cavity528 is configured to hold approximately 1.5 mL of aerosol precursorcomposition. In other embodiments, the reservoir cavity 528 isconfigured to hold about 1 ml or more, about 2 ml or more, about 5 ml ormore, or about 10 ml or more of the aerosol precursor composition.

In some implementations, the liquid composition may include one or moreflavorants. As used herein, reference to a “flavorant” refers tocompounds or components that can be aerosolized and delivered to a userand which impart a sensory experience in terms of taste and/or aroma.Example flavorants include, but are not limited to, vanillin, ethylvanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry,peach and citrus flavors, including lime and lemon), maple, menthol,mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender,cardamom, ginger, honey, anise, sage, rosemary, hibiscus, rose hip,yerba mate, guayusa, honeybush, rooibos, yerba santa, bacopa monniera,gingko biloba, withania somnifera, cinnamon, sandalwood, jasmine,cascarilla, cocoa, licorice, and flavorings and flavor packages of thetype and character traditionally used for the flavoring of cigarette,cigar, and pipe tobaccos. Syrups, such as high fructose corn syrup, alsocan be employed. Example plant-derived compositions that may be suitableare disclosed in U.S. Pat. No. 9,107,453 and U.S. Pat. App. Pub. No.2012/0152265 both to Dube et al., the disclosures of which areincorporated herein by reference in their entireties. The selection ofsuch further components are variable based upon factors such as thesensory characteristics that are desired for the smoking article, andthe present disclosure is intended to encompass any such furthercomponents that are readily apparent to those skilled in the art oftobacco and tobacco-related or tobacco-derived products. See, e.g.,Gutcho, Tobacco Flavoring Substances and Methods, Noyes Data Corp.(1972) and Leffingwell et al., Tobacco Flavoring for Smoking Products(1972), the disclosures of which are incorporated herein by reference intheir entireties. It should be understood that reference to a flavorantshould not be limited to any single flavorant as described above, andmay, in fact, represent a combination of one or more flavorants.

As shown in the figures, the cartridge 500 of the depictedimplementation also includes a base member 514, which is configured toengage and cover the open distal end of the reservoir cavity 528 of thetank 510. The lower seal 512 of the depicted implementation isconfigured form a substantially air tight and liquid tight seal betweena lower portion of the tank 510 and the bottom cap 526 (see also FIG. 20), in particular, the lower seal 512 is configured to be located withina groove on an outer surface of the base member 514 so as to facilitatea substantially air tight and liquid tight seal between the base member514 and tank 510. In various implementations, the lower seal 512 may bemade of silicone rubber, boron nitride (BN) rubber, natural rubber,thermoplastic polyurethane, or another resilient material. In thedepicted implementation, the base member 514 may be made of a moldedpolymer material, such as, for example, a molded plastic material (e.g.,a copolyester material, such as, for example, Tritan™ copolyester,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof), although other materials are possible. The basemember 514 of the depicted implementation also includes a plurality ofslots (see also FIG. 17 ) that are configured to provide liquid flowpassages for the liquid composition contained in the reservoir cavity528 of the tank 510 in order to facilitate transfer of the liquid to theliquid transport element 516. In some implementations, the slots mayalso provide retention of some liquid even when the bulk liquidcomposition in the reservoir cavity 528 is not in contact with the basemember 514 (such as, for example, when the aerosol delivery device isupside down).

As shown in the figures, the liquid transport element 516 is disposedwithin the base member 514 and extends between the liquid composition inthe reservoir cavity 528 and the heating member 518 (see also FIG. 20 ).In the depicted implementation, the liquid transport element 516 isformed of a cotton material and, when installed in the cartridge 500,has a curved shape. In other implementations, however, the liquidtransport element 516 may have other shapes and may be formed of avariety of materials configured for transport of a liquid, such as bycapillary action. For example, in some implementations the liquidtransport element may be formed of fibrous materials (e.g., organiccotton, cellulose acetate, regenerated cellulose fabrics, glass fibers),porous ceramics, porous carbon, graphite, porous glass, sintered glassbeads, sintered ceramic beads, capillary tubes, or the like. In otherimplementations, the liquid transport element may be any material thatcontains an open pore network (i.e., a plurality of pores that areinterconnected so that fluid may flow from one pore to another in aplurality of direction through the element). As further discussedherein, some implementations of the present disclosure may particularlyrelate to the use of non-fibrous transport elements. As such, fibroustransport elements may be expressly excluded. Alternatively,combinations of fibrous transport elements and non-fibrous transportelements may be utilized. Representative types of substrates, reservoirsor other components for supporting the aerosol precursor are describedin U.S. Pat. No. 8,528,569 to Newton; U.S. Pat. App. Pub. Nos.2014/0261487 to Chapman et al. and 2014/0059780 to Davis et al.; andU.S. Pat. App. Pub. No. 2015/0216232 to Bless et al.; which areincorporated herein by reference in their entireties. Additionally,various wicking materials, and the configuration and operation of thosewicking materials within certain types of electronic cigarettes, are setforth in U.S. Pat. No. 8,910,640 to Sears et al.; which is incorporatedherein by reference in its entirety. In some implementations, the liquidtransport element may be formed partially or completely from a porousmonolith, such as a porous ceramic, a porous glass, or the like. Examplemonolithic materials suitable for use according to embodiments of thepresent disclosure are described, for example, in U.S. Pat. App. SerialNo. 14/988,109, filed Jan. 5, 2016, and US Pat. No. 2014/0123989 toLaMothe, the disclosures of which are incorporated herein by referencein their entireties.

As shown in the figures, the heating member 518 of the depictedimplementation is also configured to be disposed within the base member514. In particular, the heating member 518 of the depictedimplementation comprises a heating element that has a substantially flatprofile. While in some implementations the heating member may maintain asubstantially flat profile when installed in a cartridge, when theheating member 518 of the depicted implementation is installed in thecartridge 500 it has a curved or bowed shape corresponding to the curvedshape of the liquid transport element 516 (see also FIG. 20 ). In such amanner, the heating member 518 in the installed position contacts abottom surface of the liquid transport element 516. In the depictedimplementation, the curved form of the flat heating member 518 mayprovide a large ratio of cross-sectional flow area to flow path lengththrough the liquid transport element 516. This may provide increasedperformance with respect to delivery of the liquid composition to theliquid transport element 516. When installed, edges of the heatingmember 518 are configured to engage the base member 514 such that theheating member 518 maintains its curved shape. In such a manner, thecurvature of the heating member 518 may also provide a compressive forceagainst the liquid transport element 516. In addition, the springrecover force of the heating member 518 allows the edges of the heatingmember 518 to locate or lock into the base member 514, which may reduceor eliminate any need for additional features configured to hold theheating member 518 in the base member 514 from the other side. Theinstalled curvature of the heating member 518 may also bias deflectionof the heating member 518 that may occur with thermal expansion towardsthe liquid transport element 516, thus helping to maintain thermalcontact between the heating member 518 and the liquid transport element516. In the depicted implementation, the liquid transport element 516and the heating member 518 comprise a heating assembly 534, which,together with the base member 514 and the bottom cap 526, define avaporization chamber 532.

It should be noted that some implementations need not include a heatingassembly, but, rather, may include an atomization assembly configured togenerate an aerosol in another manner. Some examples of atomizationassemblies that generate aerosols in other ways can be found, forexample, in U.S. App. No. 16/544,326, filed on Aug. 19, 2019, and titledDetachable Atomization Assembly for Aerosol Delivery Device, which isincorporated herein by reference in its entirety.

In the depicted implementation, the heating member 518 may be made of ametal material, such as a stainless steel material, including, but notlimited to, 316L, 316, 304, or 304L stainless steel. In otherimplementations, the heating member may be made of a different material,such as, for example, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide(MoSi₂), molybdenum silicide (MoSi), Molybdenum disilicide doped withAluminum (Mo(Si,Al)₂), titanium, platinum, silver, palladium, alloys ofsilver and palladium, graphite and graphite-based materials (e.g.,carbon-based foams and yarns). In further implementations, the heatingmember may be formed from conductive inks, boron doped silica, and/orceramics (e.g., positive or negative temperature coefficient ceramics).Other types of heaters may also be utilized, such as laser diodes ormicroheaters. A laser diode can be configured to deliver electromagneticradiation at a specific wavelength or band of wavelengths that can betuned for vaporization of the aerosol precursor composition and/or tunedfor heating a liquid transport element via which the aerosol precursorcomposition may be provided for vaporization. The laser diode canparticularly be positioned so as to deliver the electromagneticradiation within a chamber, and the chamber may be configured to beradiation-trapping (e.g., a black body or a white body). Suitablemicroheaters are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety. Microheaters,for example, can comprise a substrate (e.g., quartz, silica) with aheater trace thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt,Pt/Ti, boron-doped silicon, or other metals or metal alloys), which maybe printed or otherwise applied to the substrate. A passivating layer(e.g., aluminum oxide or silica) may be provided over the heater trace.Other heaters are described in U.S. Pat. App. Pub. No. 2016/0345633 toDePiano et al., which is incorporated herein by reference in itsentirety.

Although in other implementations additional and/or differing contactfeatures may be provided, the heating member 518 of the depictedimplementation includes a pair of contact holes 531A, 531B that areconfigured to connect the heating member 518 to the heater connectors520A, 520B of the cartridge 500. In depicted implementation, the heaterconnectors 520A, 520B are made of a conductive material and are platedwith nickel and/or gold. Examples of conductive materials include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. In the depicted implementation, the contact holes531A, 531B are configured to have an inner diameter that is less than anouter diameter of the mating portions of the heater connectors 520A,520B. In some implementations, the contact holes may include one or morefeatures (e.g., one or more fingers or extensions) that create aneffective inner diameter that is less than an outer diameter of themating portion of the heater connectors 520A, 520B. In such a manner,the contact holes 531A, 531B of the heating member 518 may create aninterference fit with the upper ends of the heater connectors 520A, 520Bsuch that the heating member 518 may maintain electrical contact withthe heater connectors 520A, 520B. In the depicted implementation, theheater connectors 520A, 520B are insert-molded into the bottom cap 526.

The bottom cap 526 of the depicted implementation is configured to besecured to the distal end of the tank 510 via an ultrasonic weldingprocess; however, other attachment methods are possible (e.g., viaadhesives, heat staking/welding, snap-fit, etc.). In the depictedimplementation, the bottom cap 526 of the cartridge 500 includes acartridge air inlet channel 530, which is located in an approximatecenter of a bottom surface of the bottom cap 526. Although otherconfigurations are possible, in the depicted implementation thecartridge air inlet channel 530 has a nozzle-like shape. In particular,the cartridge air inlet channel 530 of the depicted implementationincludes a first portion (proximate the bottom surface of the bottom cap526), which has a substantially cylindrical shape and a second portion,which has a substantially conical shape and leads to the vaporizationchamber 532. In such a manner, the internal diameter of the cartridgeair inlet channel 530 decreases before leading to the vaporizationchamber 532. This configuration may help to keep the air inlet channel530 relatively clear of liquid build-up leading into the vaporizationchamber 532.

Although other configurations are possible, the cartridge 500 of thedepicted implementation also includes a pair of metal inserts 524A, 524Bthat are positioned in the bottom cap 526 and are configured to beexposed through the bottom surface thereof. In the depictedimplementation, the metal inserts 524A, 524B are insert-molded into thebottom cap 526. In some implementations, the metal inserts 524A, 524Bmay be configured for a press or snap fit connection with the bottom cap526. In the depicted implementation, the metal inserts 524A, 524B aremade of stainless steel plated with nickel; however, in otherimplementations the metal inserts may be made of any material configuredto be attracted by a magnet, such as various ferromagnetic materials,including, but not limited, to iron, nickel, cobalt, alloys such assteel, and/or any combination thereof.

As noted above, when the cartridge 500 is coupled with the cartridgereceiving chamber 430 of the control device 400, mechanical andelectrical connections are created between the cartridge 500 and thecontrol device 400. In particular, when the cartridge 500 of thedepicted implementation is coupled with the upper frame 406 of thecontrol device 400, a magnetic connection is created between the magnets446A, 446B located in the upper frame 406 and the metal inserts 524A,524B located in the bottom cap 526 of the cartridge 500. In addition,when the cartridge 500 of the depicted implementation is coupled withthe inner frame 406, an electrical connection is created between thepair of conductive pins 436A, 436B of the control device 400 and theheater connectors 520A, 520B of the cartridge 500. Thus, when thecartridge 500 of the depicted implementation is coupled with the controldevice 400, the cartridge 500 is mechanically biased into connectionwith the control device 400 such that electrical connection ismaintained between the cartridge 500 (and, in particular the heatingassembly 534) and the control device (and in particular, the controlcomponent 414 and the battery 416).

When the cartridge 500 of the depicted implementation is coupled withthe control device 400, the electrical connection between the controldevice 400 and the heating member 518 of the cartridge 500 (via theconductive pins 436A, 436B of the control device 400 and the heaterconnectors 520A, 520B of the cartridge) allows the control body 400 todirect electrical current to the heating member 518. In the depictedimplementation, this may occur when a puff on the aerosol deliverydevice is detected (or, in other implementations, via actuation by theuser, such as, for example, via a pushbutton). When a user of theaerosol device of the depicted implementation draws on the mouthpiece502, inlet airflow is directed into the device via a gap between thecartridge 500 and the control device 400. In the depictedimplementation, the gap comprises a peripheral gap that extends aroundsubstantially the entire periphery of the cartridge 500. It should beunderstood that in other implementations, the gap need not extend aroundthe entire periphery of the cartridge, for example in someimplementations the gap may comprise one or more gaps that extend arounda portion of the periphery of the cartridge rather than the entireperiphery, and in some implementations, the gap may comprise one or moreindividual holes. In the depicted implementation, the gap originates atan interface between an outside surface of the cartridge 500 and aninside surface of the control device 400. In particular, the gaporiginates at the interface of an outer surface of the mouthpiece 502 ofthe cartridge 500 and a top edge of the outer wall 404 of the housing402 of the control device 400.

In the depicted implementation, the gap between the cartridge 500 andthe control device 400 is established and maintained by features of thecartridge 500 and the control device 400. Although other configurationsare possible, the upper frame 406 of the depicted implementationincludes a plurality of protuberances that are spaced around an innersurface of the upper frame 406 and that are configured to laterallyposition the cartridge 400. In the depicted implementation, theplurality of protuberances comprise a plurality of raised elongatebosses that extend from an approximate top of the upper frame 406 to arecessed surface thereof. When the cartridge 500 of the depictedimplementation is coupled with the control device 400, the plurality ofprotuberances of the upper frame 406 contact an outer surface of thecartridge 500 (and in particular, an outer surface of the mouthpiece 502and/or an outer surface of the tank 510 and/or an outer surface of thebottom cap 526). In such a manner, the protuberances position thecartridge 500 laterally with respect to the upper frame 406, thusestablishing and maintaining the gap. It should be understood that inother implementations, the protuberances may take other forms(including, for example, one or more bumps), and may be located on oneor more components of the cartridge rather than (or in addition to) thecontrol device.

As a user draws on the device, the air that enters the gap between thecartridge 500 and the control device 400 travels downward around theoutside of the cartridge 500 and below the bottom cap 526 thereof. Inthe depicted implementation, inlet air is permitted to travel below thebottom cap 526 due to the vertical position of the cartridge 500 withrespect to the bottom of the cartridge receiving chamber 430. Inparticular, the vertical position of the cartridge 500 of the depictedimplementation is established using one or more of location featuresthat extend upward from the recessed surface of the upper frame 406, atleast one of which is configured to contact the bottom surface of thebottom cap 526 when the cartridge 500 is coupled with the control device400. In such a manner, when the cartridge 500 is received into thecontrol device 400, the gap between the cartridge 500 and the controldevice 400 is also established between the bottom of the bottom cap 526and the recessed surface of the upper frame 406.

As noted above, although other configurations are possible, the bottomcap 526 of the depicted implementation includes an inlet channel 530that is located in an approximate center of the bottom surface of thebottom cap 526. Because of the gap established between the bottom of thebottom cap 526 and the recessed surface of the upper frame 406, inletair that travels around the outside of the cartridge 500 and below thebottom cap 526 enters the cartridge 500 through the inlet channel 530 ofthe bottom cap 526. The air that enters through the inlet channel 530then enters the vaporization chamber 532 of the cartridge. As the air isdrawn through the inlet channel 530 into the cartridge 500, the pressuresensor 440 of the control device 400 detects the draw. When a draw isdetected by the pressure sensor 440, the control component 414 directscurrent through the heating member 518 in order to heat the heatingmember 518. As the heating member 518 heats, at least a portion of theliquid composition contained in the liquid transport element 516 isvaporized in the vaporization chamber 532. Accordingly, aerosol producedin the vaporization chamber 532 may then directed to the user. Inparticular, as the air enters the cartridge 500 via the air inletchannel 530, the air travels through the vaporization chamber 532 whereit mixes with the vaporized liquid composition and becomes the aerosol.Due to the geometry of the vaporization chamber 532 and the bottom cap526, the aerosol is split into two separate paths that extend throughthe inside of the bottom cap 526 and then through aerosol flow tubesthat are defined on opposite sides of the reservoir cavity 528 of thetank 510. This relatively tortuous configuration may increase theeffective flow path length and area for heat sinking, thus providingincreased cooling of the aerosol stream prior to reaching the user. Thetwo aerosol paths converge at the proximal end of the tank 510 and belowthe upper aerosol channel insert 506. The recombined aerosol then flowsthrough the upper aerosol channel insert 506 and out of the exit portal515 of the mouthpiece 500, to the user. It should be understood that theaerosol passages downstream from the air inlet channel 530 inlet areconfigured to be oversized, in order to minimize any additional systempressure drop created by these passages.

Although other configurations are possible, in the depictedimplementation, the upper aerosol channel insert 506 is configured toabsorb liquid formed by deposition and/or condensation from aerosolformed in the vaporization chamber 532, and is configured to have rigidor semi-rigid properties. As such, the upper aerosol channel insert 506of the depicted implementation may be made of a fibrous, sinteredbeaded, or open cell foam material. For example, in someimplementations, the upper aerosol channel insert may be made of afibrous bonded polyethylene (PE) or polyethylene terephthalate (PET)material. In such a manner, the upper aerosol channel insert 506 may beconfigured for a press or snap fit attachment with the mouthpiece 502.The upper aerosol channel insert 506 is also configured to help toprevent accumulation of liquid from exiting the cartridge 500 throughthe mouthpiece 502. In addition, the upper aerosol channel insert 506 islocated in such a way that aerosol produced in the vaporization chamber532 passes through the insert 506 just prior to exiting the cartridge500. In the depicted implementation, the inside cavity of the upperaerosol channel insert 506 may also serve as a cooling chamber withinwhich the formed aerosol can be allowed to expand and/or cool beforepassing through the exit portal 515. In some implementations, thevaporization chamber 532 and the cooling chamber may be configured tohave a defined relative volume ratio.

FIGS. 21A and 21B illustrate subassemblies of the cartridge of FIG. 18 ,according to example implementations of the present disclosure. Inparticular, FIG. 21A illustrates a bottom cap subassembly 545 and a tanksubassembly 547, and FIG. 21B illustrates a lower subassembly 551 and amouthpiece subassembly 549. In the depicted implementation, the bottomcap subassembly 545 comprises the bottom cap 526, the metal inserts524A, 524B, the heater connectors 520A, 520B, the heating member 518,the liquid transport element 516, the base member 514, and the lowercartridge seal 512. In the depicted implementation, the metal inserts524A, 524B and the heater connectors 520A, 520B are insert-molded intothe bottom cap 526. In addition, the lower cartridge seal 512 isstretched around the base member 514 such that it is positioned in thegroove thereof. The liquid transport element 516 is inserted into thebase member 514 and the heating member is press-fit into the base member514 such that the contact holes 531A, 531B press around respectiveportions of the heater connectors 520A, 520B and the heating member 518bends into a curved shape, therein also trapping and bending the liquidtransport element 516 into a curved shape. The tank subassembly 547 ofthe depicted implementation comprises the tank 510 into which the liquidcomposition has been filled via the open end of the tank 510.

In the depicted implementation, the lower subassembly 551 of FIG. 21B isassembled by joining the bottom cap subassembly 545 to the tanksubassembly 547. In particular, the bottom cap subassembly 545 of thedepicted implementation is joined to the tank subassembly 547 via asubstantially continuous ultrasonic weld. In the depictedimplementation, the mouthpiece subassembly 549 comprises the mouthpiece502, the mouthpiece insert 504, the aerosol channel insert 506, and thecartridge seal 508. The mouthpiece subassembly 549 of the depictedimplementation is assembled by pressing the mouthpiece insert 504 intothe mouthpiece 502, pressing the cartridge seal 508 into the mouthpiece502, and pressing the aerosol channel insert 506 into the cartridge seal508. In the depicted implementation, the final assembly of the cartridge500 occurs by snapping the mouthpiece subassembly 549 onto the lowersubassembly 551 via the groove feature 541 of the outer surface of thetank 510 and the ridge feature of the inner surface of the mouthpiece502.

FIG. 22 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to another example implementationof the present disclosure. As shown in the figure, the control device600 of the depicted implementation generally includes a housing 602defining an outer wall 604, an upper frame 606, an upper frame seal 608,a pressure sensor seal 610, a lower frame 612, a control component 614,a battery 616, a vibration motor 618, a motor housing 620, a pin seal622, an end cap 624, a light diffuser 626, and a vent 645. The controldevice 600 of the depicted implementation also includes a front foam pad631, a plurality of side foam pads 637, and an insulator 639. In thedepicted implementation, the front foam pad 631 is configured to bedisposed between the battery 616 and the control component 614, and theside foam pads 437 are configured to be disposed on opposite sides ofthe battery 616. In some implementations, the control device may includeone or more other seals, which may include, for example, an upperchassis seal and/or a lower chassis seal.

The arrangement of the components of the control device 600 isillustrated in FIG. 23 , which depicts a section view of the controldevice, according to an example implementation of the presentdisclosure. In particular, FIG. 23 illustrates a front section view ofthe control device 600. As illustrated in the figure, the upper frame606 of the control device 600 defines a cartridge receiving chamber 630within which a cartridge may be coupled. The control device 600 alsoincludes a pair of opposite indication windows 632 that are definedthrough the outer wall 404 of the housing 602, as well as through theupper frame 606. It should be noted, however, that is someimplementations there need not be any indication windows. Forimplementations that include indication windows, such indication windowsmay provide a user with the ability to view one or more components(and/or conditions thereof) of an installed cartridge. It will beappreciated, however, that the illustrated indication windows 632 areprovided by way of example and not by way of limitation. For example,alternative implementations may include an indication window having adifferent shape than that illustrated. As another example, someimplementations may include only a single indication window. In thedepicted implementation, the upper frame 606 and the housing 602represent different parts; however, in other implementations, the upperframe and the housing may be continuously formed such that they comprisethe same part.

In the depicted implementation, the housing 602 comprises a metalmaterial, such as, for example, aluminum; however, in otherimplementations the housing may comprise a metal alloy material, and instill other implementations the housing may comprise a molded polymermaterial. In the depicted implementation, one or more of the upper frame606, lower frame 612, and end cap 624 may be made of a molded polymermaterial, such as, for example, a molded plastic material (e.g.,polybutylene terephthalate (PBT), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof). In other implementations, oneor more of these components may be made of other materials, including,for example, metal materials (e.g., aluminum, stainless steel, metalalloys, etc.), glass materials, ceramic materials (e.g., alumina,silica, mullite, silicon carbide, silicon nitride, aluminum nitride,etc.), composite materials, and/or any combinations thereof.

In the depicted implementation, the lower frame 612 is configured tocontain the battery 616 in an interior area thereof. In the depictedimplementation, the battery may comprise a lithium polymer (LiPo)battery; however various other batteries may be suitable. Some otherexamples of batteries that can be used according to the disclosure aredescribed in U.S. Pat. App. Pub. No. 2010/0028766 to Peckerar et al.,the disclosure of which is incorporated herein by reference in itsentirety. In some implementations, other types of power sources may beutilized. For example, in various implementations a power source maycomprise a replaceable battery or a rechargeable battery, solid-statebattery, thin-film solid-state battery, rechargeable supercapacitor orthe like, and thus may be combined with any type of rechargingtechnology, including connection to a wall charger, connection to a carcharger (e.g., cigarette lighter receptacle, USB port, etc.), connectionto a computer, such as through a universal serial bus (USB) cable orconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a USBconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C as may be implemented ina wall outlet, electronic device, vehicle, etc.), connection to aphotovoltaic cell (sometimes referred to as a solar cell) or solar panelof solar cells, a wireless charger, such as a charger that usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)), or a wireless radio frequency (RF) based charger, andconnection to an array of external cell(s) such as a power bank tocharge a device via a USB connector or a wireless charger. An example ofan inductive wireless charging system is described in U.S. Pat. App.Pub. No. 2017/0112196 to Sur et al., which is incorporated herein byreference in its entirety. In further implementations, a power sourcemay also comprise a capacitor. Capacitors are capable of dischargingmore quickly than batteries and can be charged between puffs, allowingthe battery to discharge into the capacitor at a lower rate than if itwere used to power the heating member directly. For example, asupercapacitor - e.g., an electric double-layer capacitor (EDLC) - maybe used separate from or in combination with a battery. When used alone,the supercapacitor may be recharged before each use of the article.Thus, the device may also include a charger component that can beattached to the smoking article between uses to replenish thesupercapacitor. Examples of power supplies that include supercapacitorsare described in U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,which is incorporated herein by reference in its entirety.

The control device 600 of the depicted implementation includes a controlmechanism in the form of the control component 614, which is configured,in part, to control the amount of electric power provided to the heatingmember of the cartridge. Although other configurations are possible, thecontrol component 614 of the depicted implementation comprises a circuitboard 634 (e.g., a printed circuit board (PCB)) that includes both rigidand flexible portions. In particular, the circuit board 634 of thedepicted implementation includes a rigid central section 615 and tworigid end sections comprising a proximal end section 617 and a distalend section 619, with each of the end sections 617, 619 being connectedto the central section 615 by a respective flexible connection. In sucha manner, when the lower frame 612, battery 616, and circuit board 634are assembled into the control device 600, the central section 615 ofthe circuit board 634 is configured to be disposed proximate a majorsurface of the battery 616, and the two end sections 617, 619 areconfigured to be disposed substantially perpendicular to the centralsection 615. In particular, the proximal end section 617 of the circuitboard 634 is configured to extend over the top of the lower frame 612,and the distal end section 619 is configured to extend over the bottomof the lower frame 612. The lower frame 612 of the control device 600 isalso configured to contain the motor housing 620, into which thevibration motor 618 is received. In various implementations, thevibration motor 618 may provide haptic feedback relating to variousoperations of the device.

The central section 615 of the depicted implementation also includes anindicator in the form of a light source 621. In some implementations,the light source may comprise, for example, at least one light emittingdiode (LED) capable of providing one or more colors of light. In otherimplementations, the light source may be configured to illuminate inonly one color, while in other implementations, the light source may beconfigured to illuminate in variety of different colors. In still otherimplementations, the light source may be configured to provide whitelight. In the depicted implementation, the light source 621 comprises anRGB (red, green, blue) LED that is configured to provide a variety ofcolors of light, including white light. The central section 615 of thedepicted circuit board 634 also includes electrical contacts 623 thatare configured to operatively connect the circuit board 634 to thevibration motor 618. Other types of electronic components, structuresand configurations thereof, features thereof, and general methods ofoperation thereof, are described in U.S. Pat. Nos. 4,735,217 to Gerth etal.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.;6,040,560 to Fleischhauer et al.; 7,040,314 to Nguyen et al. and8,205,622 to Pan; U.S. Pat. App. Pub. Nos. 2009/0230117 to Fernando etal., 2014/0060554 to Collet et al., and 2014/0270727 to Ampolini et al.;and U.S. Pat. App. Pub. No. 2015/0257445 to Henry et al.; which areincorporated herein by reference. Yet other features, controls orcomponents that can be incorporated into aerosol delivery devices of thepresent disclosure are described in U.S. Pat. Nos. 5,967,148 to Harriset al.; 5,934,289 to Watkins et al.; U.S. Pat. No. 5,954,979 to Countset al.; 6,040,560 to Fleischhauer et al.; 8,365,742 to Hon; 8,402,976 toFernando et al.; U.S. Pat. App. Pub. Nos. 2010/0163063 to Fernando etal.; 2013/0192623 to Tucker et al.; 2013/0298905 to Leven et al.;2013/0180553 to Kim et al., 2014/0000638 to Sebastian et al.,2014/0261495 to Novak et al., and 2014/0261408 to DePiano et al.; whichare incorporated herein by reference in their entireties.

In the depicted implementation, the vent 645 is configured to beinstalled on the inside of the housing 602 such that it covers theaperture 625. As such, in the depicted implementation one side of thevent 645 may include a pressure sensitive adhesive. In the depictedimplementation, the vent 645 comprises a breathable membrane material,such as, for example, a Gore-Tex® material; however, other suitablematerials are possible. In the depicted implementation, the light source621 is covered by the light diffuser 626, a portion of which isconfigured to be received by the end cap 624. In such a manner, whenassembled, the light diffuser 626 is positioned in or proximate anaperture 625 defined in the outer wall 604 of the housing 602 andproximate a distal end thereof. In the depicted implementation, theaperture 625 comprises a narrow, elongate opening; however, in otherimplementations, the aperture may be provided in any desired shape andmay be positioned at any location on the control device 600. In someimplementations, the light diffuser 626 may comprise a transparent ortranslucent member configured to allow a user to view the light source621 from the outside of the housing 602. In the depicted implementation,the light diffuser 626 may be made of a molded polymer material, suchas, for example, a molded plastic material (e.g., polybutyleneterephthalate (PBT), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof), although other materials,including glass, are possible. In various implementations, furtherindicators (e.g., other haptic feedback components, an audio feedbackcomponent, or the like) can be included in addition to or as analternative to the indicators included in the depicted implementation.Additional representative types of components that yield visual cues orindicators, such as LED components, and the configurations and usesthereof, are described in U.S. Pat. Nos. 5,154,192 to Sprinkel et al.;8,499,766 to Newton and 8,539,959 to Scatterday; U.S. Pat. App. Pub. No.2015/0020825 to Galloway et al.; and U.S. Pat. App. Pub. No.2015/0216233 to Sears et al.; which are incorporated herein by referencein their entireties.

Although other configurations are possible, the proximal end section 617of the circuit board 634 of the depicted implementation includes a pairof conductive pins 636A, 636B, as well as a pressure sensor 640. In thedepicted implementation, the conductive pins 636A, 636B comprisespring-loaded pins (e.g., electrical pogo pins) that extend through theupper frame 606 such that portions of the ends of the pins 636A, 636Bextend into the cartridge receiving chamber 630 and are biased in thatposition due to the force of the internal springs of the conductive pins636A, 636B. In such a manner, when a cartridge is coupled with thecontrol device 600, the conductive pins 636A, 636B are configured tocontact corresponding features of the cartridge and deflect downward(e.g., toward the lower frame 612) against the force of the springs,thus operatively connecting the installed cartridge with the controlcomponent 614 and the battery 616. In the depicted implementation, theconductive pins 636A, 636B comprise gold plated metal pins; however,other materials or combinations of materials, which may also includecoatings and/or platings of electrically conductive materials, arepossible. Examples of electrically conductive materials, include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. Although other profiles are possible, the ends ofthe conductive pins 636A, 636B of the depicted implementation have arounded profile such that deflection of the conductive pins 636A, 636Bis facilitated when a cartridge is inserted into the cartridge receivingchamber 630. In other implementations, the conductive pins may bepositioned in other locations of the cartridge receiving chamber 630,such as, for example, proximate the top of the cartridge receivingchamber 630. In other implementations, the conductive pins may bepositioned at a point on the sides of the upper frame between theproximal end of the outer housing and the bottom wall of the upperframe. Further, in still other implementations the conductive pins maybe positioned between a midpoint of the sidewalls and the proximal endof the outer housing (i.e., in an upper half of the sidewalls).Alternatively, the conductive pins may be positioned between a midpointof the sidewalls and the bottom wall of the inner frame wall (e.g., in alower half of the sidewalls). Moreover, in still other implementations,the conductive pins may be present at any position of the upper frame.

In various implementations, the aerosol delivery device may include anairflow sensor, pressure sensor, or the like. As noted above, thecontrol component 614 of the depicted implementation includes a pressuresensor 640, which is positioned proximate and below the cartridgereceiving chamber 630. The position and function of the pressure sensor640 of the depicted implementation will be described below; however, inother implementations an airflow or pressure sensor may be positionedanywhere within the control device 600 so as to subject to airflowand/or a pressure change that can signal a draw on the device and thuscause the battery 616 to delivery power to the heating member of acartridge. Various configurations of a printed circuit board and apressure sensor, for example, are described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., the disclosure of which is incorporatedherein by reference in its entirety. In the absence of an airflowsensor, pressure sensor, or the like, an aerosol delivery device may beactivated manually, such as via a pushbutton that may be located on thecontrol device and/or the cartridge. For example, one or morepushbuttons may be used as described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., which is incorporated herein by referencein its entirety. Likewise, a touchscreen may be used as described inU.S. Pat. App. Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference in its entirety. As afurther example, components adapted for gesture recognition based onspecified movements of the aerosol delivery device may be used as aninput. See U.S. Pat. App. Pub. 2016/0158782 to Henry et al., which isincorporated herein by reference in its entirety.

Although not included in the depicted implementation, someimplementations may include other types of input elements, which mayreplace or supplement an airflow or pressure sensor. The input may beincluded to allow a user to control functions of the device and/or foroutput of information to a user. Any component or combination ofcomponents may be utilized as an input for controlling the function ofthe device. In some implementations, an input may comprise a computer orcomputing device, such as a smartphone or tablet. In particular, theaerosol delivery device may be wired to the computer or other device,such as via use of a USB cord or similar protocol. The aerosol deliverydevice may also communicate with a computer or other device acting as aninput via wireless communication. See, for example, the systems andmethods for controlling a device via a read request as described in U.S.Pat. App. Pub. No. 2016/0007561 to Ampolini et al., the disclosure ofwhich is incorporated herein by reference in its entirety. In suchembodiments, an APP or other computer program may be used in connectionwith a computer or other computing device to input control instructionsto the aerosol delivery device, such control instructions including, forexample, the ability to form an aerosol of specific composition bychoosing the nicotine content and/or content of further flavors to beincluded. Additional representative types of sensing or detectionmechanisms, structure and configuration thereof, components thereof, andgeneral methods of operation thereof, are described in U.S. Pat. Nos.5,261,424 to Sprinkel, Jr.; 5,372,148 to McCafferty et al.; and PCT WO2010/003480 to Flick; which are incorporated herein by reference intheir entireties.

In the depicted implementation, the pressure sensor seal 610 isconfigured to cover the pressure sensor 640 to protect it from anyliquid and/or aerosol from an installed cartridge. In such a manner, thepressure sensor seal 610 of the depicted implementation (as well asother sealing members, including the motor housing 620, the pin seal622, and/or an end cap seal 643) may be made of silicone rubber, boronnitride (BN) rubber, natural rubber, thermoplastic polyurethane, oranother resilient material. In some implementations, the upper portionsof the end cap pins are configured to engage with the lower frame. Forexample, in some implementations the upper portions of the end cap pinsare configured to create an interference or press-fit engagement withcorresponding slotted openings in the lower frame. In variousimplementations, the interface between the end cap and the housing(e.g., via the interface between the end cap seal and the inner surfaceof the outer housing wall and/or the upper portions of the end cap pinsand the lower frame) may create a press-fit engagement with the housingthat is configured to be releasable so that the end cap (or end capassembly) may be removable. In some implementations the control devicemay include one or more components configured to meet battery outgassingrequirements under UL 8139. For example, the control device may includean end cap configured to eject in the event that sudden pressurizationoccurs within the control device enclosure. In one implementation, theend cap may include retaining pins that extend substantiallyperpendicularly from a wall of the end cap. The retaining pins may beconfigured to mate with receiving features (e.g., holes) in a frame ofthe control device to establish a friction fit or press fit that may beovercome if an internal pressure within the control device housingexceeds a defined internal pressure.

Although other configurations are possible, the distal end section 619of the circuit board 634 includes the external connection element 638.In various implementations, the external connection element 638 may beconfigured for connecting to an external connector and/or a dockingstation or other power or data source. For example, in someimplementations an external connector may comprise first and secondconnector ends that may be interconnected by a union, which may be, forexample, a cord of variable length. In some implementations, the firstconnector end may be configured for electrical and, optionally,mechanical connection with the device, and the second connector end maybe configured for connection to a computer or similar electronic deviceor for connection to a power source. An adaptor including a USBconnector at one end and a power unit connector at an opposing end isdisclosed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference in its entirety. In the depictedimplementation, the pin seal 622 is configured to seal the interfacebetween the external connection element 638 and the end cap 624. In thedepicted implementation, one or more pins of the external connectionelement 638 may extend through the end cap 624 of the control device asnoted above. In the depicted implementation, the end cap 624 alsoincludes a pair of end cap pins 641A, 641B that may be affixed to theend cap 624. For example, in some implementations, the end cap pins641A, 641B may be insert-molded into the end cap 624. In someimplementations, a bottom surface of the end cap pins 641A, 641B (which,in some implementations, may be flat) may be configured to provideattraction for magnets contained in an external charger assembly. Insuch a manner, the end cap pins 641A, 641B may be made of any materialconfigured to be attracted by a magnet, such as various ferromagneticmaterials, including, but not limited, to steel, iron, nickel, cobalt,other alloys, and/or any combination thereof.

The upper frame 606 of the depicted implementation includes a pair ofmagnets 646A, 646B that are exposed in the cartridge receiving chamber630. In various implementations, the magnets 646A, 646B may comprise anytype of magnets, including rare earth magnets. For example, in someimplementations, one or more of the magnets may comprise Neodymiummagnets (also known as NdFeB, NIB, or Neo magnets). In variousimplementations, different grades of Neodymium magnets may be used,including, for example, N35, N38, N40, N42, N45, N48, N50, and/or N52grades. In other implementations, one or more of the magnets maycomprise Samarium Cobalt magnets (also known as SmCo magnets). In stillother implementations, one or more of the magnets may compriseCeramic/Ferrite magnets. In other implementations, one or more of themagnets may comprise Aluminum-Nickel-Cobalt (AlNiCo) magnets. In any ofthe foregoing implementations, one or more of the magnets may be platedand/or coated. For example, in some implementations, one or more of themagnets may be coated with nickel. In other implementations, one or moremagnets may be coated with one or more of zinc, tin, copper, epoxy,silver and/or gold. In some implementations, one or more of the magnetsmay be coated with combinations of these materials. For example, in oneimplementation, one or more of the magnets may be coated with nickel,copper, and nickel again. In another implementation, one or more of themagnets may be coated with nickel, copper, nickel, and a top coating ofgold.

FIG. 24 illustrates an exploded perspective view of a cartridge 700,according to another example implementation of the present disclosure.FIG. 25 illustrates a front section view of the cartridge 700, and FIG.26 illustrates a side section view of the cartridge 700. Although otherconfigurations are possible, the cartridge 700 of the depictedimplementation generally includes a mouthpiece 702, a mouthpiece insert704, an upper aerosol channel insert 706, an upper cartridge seal 708, atank 710 that defines a tank wall 711, a lower cartridge seal 712, abase member 714, a liquid transport element (e.g., a wick) 716, aheating member 718, a pair of heater connectors 720A, 720B, a pair ofmetal inserts 724A, 724B, and a bottom cap 726.

As shown in the figures, the mouthpiece 702 of the depictedimplementation defines a proximal end and a distal end, with theproximal end of the mouthpiece 702 defining an exit portal 715 therein.In the depicted implementation, the mouthpiece insert 704 is configuredto be located proximate the proximal end of the mouthpiece 702 such thatit extends through the exit portal 715 thereof. In the depictedimplementation, the mouthpiece 702 may be made of a moldable plasticmaterial, such as polypropylene, although other materials are possibleincluding, but not limited to, Tritan™ copolyester, acrylonitrilebutadiene styrene (ABS), polyethylene, polycarbonate, Polyamide (Nylon),high impact polystyrene, and combinations thereof. In the depictedimplementation, the mouthpiece insert 704 may be made of a moldedpolymer material, such as, for example, Tritan™ copolyester, althoughother materials are possible, including, but not limited to,polypropylene, acrylonitrile butadiene styrene (ABS), polyethylene,polycarbonate, Polyamide (Nylon), high impact polystyrene, andcombinations thereof. In the depicted implementation, the uppercartridge seal 708 is overmolded onto/with the mouthpiece insert 704,although in other implementations these components may representseparate parts. In the depicted implementation, the upper cartridge seal708 is configured to form a substantially air tight and liquid tightseal between the tank 710 and the mouthpiece 702. As such, the uppercartridge seal 708 may be made of thermoplastic elastomer. In otherimplementations, the upper cartridge seal may be made of othermaterials, including, but not limited to, silicone rubber, boron nitride(BN) rubber, natural rubber, thermoplastic polyurethane, or anotherresilient material. In the depicted implementation, the mouthpieceinsert 704 is configured to receive and seal the upper aerosol channelinsert 706 (see also FIGS. 25 and 26 ).

In the depicted implementation, the mouthpiece insert 704 and uppercartridge seal 708 assembly includes a flange feature such that themouthpiece insert 704 and upper cartridge seal 708 may be installed frominside the mouthpiece 702 and may be configured for a press or snap-fitconnection with the exit portal 715 and/or another portion of themouthpiece 702. In other implementations, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.). In the depicted implementation, the mouthpiece 702 is configuredto be secured to the tank 710 via snap features. For example, themouthpiece 702 of the depicted implementation includes a ridge feature743 (see FIG. 26 ) that extends around at least a portion of an innersurface thereof, and the tank 710 includes a corresponding groovefeature 741 that extends around at least a portion of an outer surfacethereof. In other implementations, these features may be reversed (e.g.,the mouthpiece may include a groove and the tank may include a ridgefeature). In still other implementations, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.).

In some implementations, the mouthpiece insert may exhibit a colorassociated with a distinctive characteristic of the cartridge. Forexample, in some implementations a cartridge of the present disclosuremay include a liquid composition that includes a distinctivecharacteristic such as, for example, a particular flavorant (asdiscussed infra), or a specific strength of nicotine, although anycharacteristic of the cartridge may be considered a distinctivecharacteristic. For the purposes of the current description, the term“color” should be interpreted broadly, for example covering any color orany shade of the same color. It should also be noted that in someimplementations, certain colors may be commonly associated withparticular distinctive characteristics (e.g., the color green may beassociated with a mint flavorant, and the color red may be associatedwith an apple flavorant); however, in other implementations, certaincolors may be associated with particular distinctive characteristicsaccording to an index or guide, which may be provided or made availableto a user. Examples of distinctive characteristics are described in U.S.Pat. App. Serial No. 16/171,920, titled Aerosol Delivery Device withFlavor Indicator, which is incorporated herein by reference in itsentirety.

The tank 710 of the depicted implementation defines a proximal end and adistal end, wherein the mouthpiece 702 is configured to engage theproximal end of the tank 710 and the bottom cap 726 is configured toengage the distal end of the tank 710. In the depicted implementation,the tank 710 also defines a reservoir cavity 728 that includes a closedproximal end and an open distal end. As such, the reservoir cavity 728of the tank 710 is configured to contain a liquid composition (e.g., ane-liquid or aerosol precursor composition) therein. The closed proximalend of the reservoir cavity 728 allows the cavity to create a reliableseal on the top side of the liquid composition column. This may preventthe seepage/entry of air into the reservoir cavity from the top end whenthe cartridge is held upright. This may also prevent air from enteringfrom the top of the liquid composition column, which may create a vacuumand may reduce the potential of the liquid composition to leak from thebottom of the tank through the liquid transport element or otherpassages.

Although other configurations are possible, in the depictedimplementation a pair of internal aerosol flow tubes 733A, 733B aredefined on opposite sides of the reservoir cavity 728 of the tank 710.In the case of an injection molded tank 710, the internal aerosol flowtubes are configured to be molded therein. As will be described in moredetail below, aerosol produced in a vaporization chamber of thecartridge 700 is configured to travel through the aerosol flow tubes fordelivery to a user.

In the depicted implementation, the tank wall 711 is configured to betransparent or translucent so that the liquid composition containedtherein may be visible externally. As such, in the depictedimplementation the entire tank wall 711 is configured to be transparentor translucent. Alternatively, in some implementations, only a portionof the tank wall or only a single side of the tank wall may betransparent or translucent while the remaining portions of the tank wallmay be substantially opaque. In other implementations, the tank wall maybe substantially opaque, and a strip extending from the proximal end ofthe tank to the distal end of the tank may be transparent ortranslucent. In further implementations, the tank wall may be colored.In some implementations, the color can be configured so that the liquidcomposition within the tank is still visible, such by using atransparent or translucent outer tank wall. In other implementations,the tank wall can be configured so that the outer tank wall hassubstantially opaque color. In the depicted implementation, the tank 710is made of Tritan™ copolyester, although in other implementations thetank may be made of other materials including, but not limited to,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof. Still other materials are possible, including, forexample, glass.

For those implementations that include an indication window in thecontrol device, at least a portion of the tank and/or at least a portionof the bottom cap may be visible when the cartridge is engaged with thecontrol device. As noted above, in some implementations at least aportion of the tank wall 711 may be configured to be at least partiallytransparent or translucent so that the liquid composition containedtherein is visible externally. Thus, in some implementations therelative amount of any liquid composition present in the tank may bevisible through the indication window when the cartridge is engaged withthe control device. In some implementations, the indication window maybe located near the proximal end of the control device and is configuredas an elongate oval shaped cut-out in the outer wall of the housing andthe upper frame of the control device. It should be understood that instill other implementations, the indication window may have any othershapes and/or locations, as described above with respect to otherdepicted implementations, and, as noted, some implementations need notinclude any indication windows.

In the depicted implementation, the tank 710, and in particular, thereservoir cavity 728, contains a liquid composition, which may includean aerosol precursor composition and/or a flavorant. Reference is madeto the above discussions of these materials and variations thereof. Asshown in the figures, the cartridge 700 of the depicted implementationalso includes a base member 714, which is configured to engage and coverthe open distal end of the reservoir cavity 728 of the tank 710. Thelower seal 712 of the depicted implementation is configured form asubstantially air tight and liquid tight seal between a lower portion ofthe tank 710 and the bottom cap 726 (see also FIGS. 25 and 26 ), inparticular, the lower seal 712 is configured to be located within agroove on an outer surface of the base member 714 so as to facilitate asubstantially air tight and liquid tight seal between the base member714 and tank 710. In the depicted implementation, the lower seal 712 ismade of silicon rubber. In other implementations, the lower seal may bemade of other materials, including, but not limited to, boron nitride(BN) rubber, natural rubber, thermoplastic polyurethane, or anotherresilient material. In the depicted implementation, the base member 714is made of Tritan™ copolyester. In other implementations, the basemember may be made of another material, including, but not limited to,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof. The base member 714 of the depicted implementationalso includes a plurality of slots 735 that are configured to provideliquid flow passages for the liquid composition contained in thereservoir cavity 728 of the tank 710 in order to facilitate transfer ofthe liquid to the liquid transport element 716. In some implementations,the slots may also provide retention of some liquid even when the bulkliquid composition in the reservoir cavity 728 is not in contact withthe base member 714 (such as, for example, when the aerosol deliverydevice is upside down).

As shown in the figures, the liquid transport element 716 is disposedwithin the base member 714 and extends between the liquid composition inthe reservoir cavity 728 and the heating member 718 (see also FIGS. 25and 26 ). In the depicted implementation, the liquid transport element716 is made of 100% cotton and, when installed in the cartridge 700, hasa curved shape. In other implementations, however, the liquid transportelement may have other shapes and may be formed of a variety ofmaterials configured for transport of a liquid, such as by capillaryaction. For example, in some implementations the liquid transportelement may be formed of fibrous materials (e.g., organic cotton,cellulose acetate, regenerated cellulose fabrics, glass fibers), porousceramics, porous carbon, graphite, porous glass, sintered glass beads,sintered ceramic beads, capillary tubes, or the like. In otherimplementations, the liquid transport element may be any material thatcontains an open pore network (i.e., a plurality of pores that areinterconnected so that fluid may flow from one pore to another in aplurality of direction through the element). As further discussedherein, some implementations of the present disclosure may particularlyrelate to the use of non-fibrous transport elements. As such, fibroustransport elements may be expressly excluded. Alternatively,combinations of fibrous transport elements and non-fibrous transportelements may be utilized. Representative types of substrates, reservoirsor other components for supporting the aerosol precursor are describedin U.S. Pat. No. 8,528,569 to Newton; U.S. Pat. App. Pub. Nos.2014/0261487 to Chapman et al. and 2014/0059780 to Davis et al.; andU.S. Pat. App. Pub. No. 2015/0216232 to Bless et al.; which areincorporated herein by reference in their entireties. Additionally,various wicking materials, and the configuration and operation of thosewicking materials within certain types of electronic cigarettes, are setforth in U.S. Pat. No. 8,910,640 to Sears et al.; which is incorporatedherein by reference in its entirety. In some implementations, the liquidtransport element may be formed partially or completely from a porousmonolith, such as a porous ceramic, a porous glass, or the like. Examplemonolithic materials suitable for use according to embodiments of thepresent disclosure are described, for example, in U.S. Pat. App. SerialNo. 14/988,109, filed Jan. 5, 2016, and US Pat. No. 2014/0123989 toLaMothe, the disclosures of which are incorporated herein by referencein their entireties.

As shown in the figures, the heating member 718 of the depictedimplementation is also configured to be disposed within the base member714. In particular, the heating member 718 of the depictedimplementation comprises a heating element that has a substantially flatprofile. While in some implementations the heating member may maintain asubstantially flat profile when installed in a cartridge, when theheating member 718 of the depicted implementation is installed in thecartridge 700 it has a curved or bowed shape corresponding to the curvedshape of the liquid transport element 716 (see also FIG. 26 ). Althoughother implementations may differ, in the depicted implementation theheating member 718 includes a first end, a second end, and a heater loopconnecting the first end and the second end. In particular, the heaterloop of the depicted implementation comprises a serpentine pattern ofheater traces that are connected at respective ends thereof and thatextend substantially transverse to a longitudinal axis of the heatingmember to connect the first end to the second end. While in someimplementations the heater traces may be solid, the heater traces of thedepicted implementation comprise a plurality of split traces. In thedepicted implementation, the edges of the heating member aresubstantially solid and the plurality of split traces are located in acentral area of the heating member. In such a manner, the heater loop ofthe depicted implementation may be configured to concentrate heat in anarea of the heating element configured to be in contact with the liquidtransport element 716.

In the depicted implementation, the heating member 718 in the installedposition contacts a bottom surface of the liquid transport element 716.In the depicted implementation, the curved form of the flat heatingmember 718 may provide a large ratio of cross-sectional flow area toflow path length through the liquid transport element 716. This mayprovide increased performance with respect to delivery of the liquidcomposition to the liquid transport element 716. When installed, edgesof the heating member 718 are configured to engage the base member 714such that the heating member 718 maintains its curved shape. In such amanner, the curvature of the heating member 718 may also provide acompressive force against the liquid transport element 716. In addition,the spring recover force of the heating member 718 allows the edges ofthe heating member 718 to locate or lock into the base member 714, whichmay reduce or eliminate any need for additional features configured tohold the heating member 718 in the base member 714 from the other side.The installed curvature of the heating member 718 may also biasdeflection of the heating member 718 that may occur with thermalexpansion towards the liquid transport element 716, thus helping tomaintain thermal contact between the heating member 718 and the liquidtransport element 716. In the depicted implementation, the liquidtransport element 716 and the heating member 718 comprise a heatingassembly 734, which, together with the base member 714 and a nozzlemember 755, define a vaporization chamber 732. In the depictedimplementation, the nozzle member 755 includes a central opening and islocated proximate the base member 726 and below the heating member 718.In the depicted implementation, the nozzle member 755 is made ofsilicone rubber although other materials are possible, including, butnot limited to, boron nitride (BN) rubber, natural rubber, thermoplasticpolyurethane, or another resilient material. In other implementations,the nozzle member may be made of other materials, including, but notlimited to, moldable plastic materials.

It should be noted that some implementations need not include a heatingassembly, but, rather, may include an atomization assembly configured togenerate an aerosol in another manner. Some examples of atomizationassemblies that generate aerosols in other ways can be found, forexample, in U.S. App. No. 16/544,326, filed on Aug. 19, 2019, and titledDetachable Atomization Assembly for Aerosol Delivery Device, which isincorporated herein by reference in its entirety.

In the depicted implementation, the heating member 718 is made of 316Lstainless steel, although other materials may be used including, but notlimited to, 316, 304, or 304L stainless steel. In other implementations,the heating member may be made of a different material, such as, forexample, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), titanium, platinum, silver, palladium, alloys of silverand palladium, graphite and graphite-based materials (e.g., carbon-basedfoams and yarns). In further implementations, the heating member may beformed from conductive inks, boron doped silica, and/or ceramics (e.g.,positive or negative temperature coefficient ceramics). Other types ofheaters may also be utilized, such as laser diodes or microheaters. Alaser diode can be configured to deliver electromagnetic radiation at aspecific wavelength or band of wavelengths that can be tuned forvaporization of the aerosol precursor composition and/or tuned forheating a liquid transport element via which the aerosol precursorcomposition may be provided for vaporization. The laser diode canparticularly be positioned so as to deliver the electromagneticradiation within a chamber, and the chamber may be configured to beradiation-trapping (e.g., a black body or a white body). Suitablemicroheaters are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety. Microheaters,for example, can comprise a substrate (e.g., quartz, silica) with aheater trace thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt,Pt/Ti, boron-doped silicon, or other metals or metal alloys), which maybe printed or otherwise applied to the substrate. A passivating layer(e.g., aluminum oxide or silica) may be provided over the heater trace.Other heaters are described in U.S. Pat. App. Pub. No. 2016/0345633 toDePiano et al., which is incorporated herein by reference in itsentirety.

Although in other implementations additional and/or differing contactfeatures may be provided, the heating member 718 of the depictedimplementation includes a pair of contact holes 731A, 731B that areconfigured to connect the heating member 718 to the heater connectors720A, 720B of the cartridge 700. In depicted implementation, the heaterconnectors 720A, 720B are made of brass and are plated with gold overnickel. In other implementations, the heater connectors may be made ofanother conductive material that may or may not be plated. Examples ofother possible conductive materials include, but are not limited to,copper, aluminum, platinum, gold, silver, iron, steel, bronze, graphite,conductive ceramic materials, and/or any combination thereof. In thedepicted implementation, the contact holes 731A, 731B are configured tohave an inner diameter that is less than an outer diameter of the matingportions of the heater connectors 720A, 720B. In some implementations,the contact holes may include one or more features (e.g., one or morefingers or extensions) that create an effective inner diameter that isless than an outer diameter of the mating portion of the heaterconnectors 720A, 720B. In such a manner, the contact holes 731A, 731B ofthe heating member 718 may create an interference fit with the upperends of the heater connectors 720A, 720B such that the heating member518 may maintain electrical contact with the heater connectors 720A,720B. In the depicted implementation, the heater connectors 720A, 720Bare insert-molded into the bottom cap 726.

The bottom cap 726 of the depicted implementation is configured to besecured to the distal end of the tank 710 via an ultrasonic weldingprocess; however, other attachment methods are possible (e.g., viaadhesives, heat staking/welding, snap-fit, etc.). In the depictedimplementation, the bottom cap 726 of the cartridge 700 includes acartridge air inlet channel 730, which is located in an approximatecenter of a bottom surface of the bottom cap 726. Although otherconfigurations are possible, in the depicted implementation thecartridge air inlet channel 730 has an oval shape and includes across-bar feature that extends across the inlet between the opening ofthe air inlet channel 730 and the vaporization chamber 732.

Although other configurations are possible, the cartridge 700 of thedepicted implementation also includes a pair of metal inserts 724A, 724Bthat are positioned in the bottom cap 726 and are configured to beexposed through the bottom surface thereof. In the depictedimplementation, the metal inserts 724A, 724B are insert-molded into thebottom cap 726. In some implementations, the metal inserts may beconfigured for a press or snap fit connection with the bottom cap. Inthe depicted implementation, the metal inserts 724A, 724B are made ofstainless steel plated with nickel; however, in other implementationsthe metal inserts may be made of any material configured to be attractedby a magnet, such as various ferromagnetic materials, including, but notlimited, to iron, nickel, cobalt, alloys such as steel, and/or anycombination thereof.

As noted above, when a cartridge is coupled with a cartridge receivingchamber of a control device, mechanical and electrical connections arecreated between the cartridge and the control device. FIG. 27illustrates a front cross section view of an aerosol delivery device,according to an example implementation of the present invention. Inparticular, FIG. 27 depicts cartridge 700 coupled with control device600. When the cartridge 700 of the depicted implementation is coupledwith the upper frame 606 of the control device 600, a magneticconnection is created between the magnets 646A, 646B located in theupper frame 606 and the metal inserts 724A, 724B located in the bottomcap 726 of the cartridge 700. In addition, an electrical connection iscreated between the pair of conductive pins 636A, 636B of the controldevice 600 and the heater connectors 720A, 720B of the cartridge 700.Thus, when the cartridge 700 of the depicted implementation is coupledwith the control device 600, the cartridge 700 is mechanically biasedinto connection with the control device 600 such that electricalconnection is maintained between the cartridge 700 (and, in particularthe heating assembly 734) and the control device (and in particular, thecontrol component 614 and the battery 616).

When the cartridge 700 of the depicted implementation is coupled withthe control device 600, the electrical connection between the controldevice 600 and the heating member 718 of the cartridge 700 (via theconductive pins 636A, 636B of the control device 600 and the heaterconnectors 720A, 720B of the cartridge) allows the control body 600 todirect electrical current to the heating member 718. In the depictedimplementation, this may occur when a puff on the aerosol deliverydevice is detected (or, in other implementations, via actuation by theuser, such as, for example, via a pushbutton). When a user of theaerosol device of the depicted implementation draws on the mouthpiece702, inlet airflow is directed into the device via a gap between thecartridge 700 and the control device 600. In the depictedimplementation, the gap comprises a peripheral gap that extends aroundsubstantially the entire periphery of the cartridge 700. It should beunderstood that in other implementations, the gap need not extend aroundthe entire periphery of the cartridge, for example in someimplementations the gap may comprise one or more gaps that extend arounda portion of the periphery of the cartridge rather than the entireperiphery, and in some implementations, the gap may comprise one or moreindividual holes. In the depicted implementation, the gap originates atan interface between an outside surface of the cartridge 700 and aninside surface of the control device 600. In particular, the gaporiginates at the interface of an outer surface of the mouthpiece 702 ofthe cartridge 700 and a top edge of the outer wall 604 of the housing602 of the control device 600.

In the depicted implementation, the gap between the cartridge 700 andthe control device 600 is established and maintained by features of thecartridge 700 and/or the control device 600. Although otherconfigurations are possible, the upper frame 606 of the depictedimplementation includes a pair of spaced protuberances located on oneside of the cartridge receiving chamber 630 and a pair of spacedchannels located on the opposite side of the cartridge receiving chamber630. In the depicted implementation, the protuberances comprise raisedelongate bosses that extend from an approximate top of the upper frame606 to a recessed surface thereof. Likewise, the channels extend from anapproximate top of the upper frame 606 to a recessed surface thereof.When the cartridge 700 of the depicted implementation is coupled withthe control device 600, the protuberances located on the inner surfaceof the cartridge receiving chamber 630, the area of the upper framebetween the channels (which, alternatively, may be considered a relativewide or large protuberance), and/or the area between the protuberancesand the channels contact an outer surface of the cartridge 700 (and inparticular, an outer surface of the mouthpiece 702 and/or an outersurface of the tank 710 and/or an outer surface of the bottom cap 726).In such a manner, these features position the cartridge 700 laterallywith respect to the upper frame 606, thus establishing and maintainingthe gap. It should be understood that in other implementations,positioning features may take other forms (including, for example, oneor more bumps), and may be located on one or more components of thecartridge rather than (or in addition to) the control device.

As a user draws on the device, the air that enters the gap between thecartridge 700 and the control device 600 travels downward around theoutside of the cartridge 700 and below the bottom cap 726 thereof. Inthe depicted implementation, inlet air is permitted to travel below thebottom cap 726 due to the vertical position of the cartridge 700 withrespect to the bottom of the cartridge receiving chamber 730. Inparticular, the vertical position of the cartridge 700 of the depictedimplementation is established using one or more of location featuresthat extend upward from the recessed surface of the upper frame 606, atleast one of which is configured to contact the bottom surface of thebottom cap 726 when the cartridge 700 is coupled with the control device600. In the depicted implementation, the location features include atleast a pair of bosses, each of which extends around a respective magnet646. In such a manner, when the cartridge 700 is received into thecontrol device 600, the gap between the cartridge 700 and the controldevice 600 is also established between the bottom of the bottom cap 726and the recessed surface of the upper frame 606.

As noted above, although other configurations are possible, the bottomcap 726 of the depicted implementation includes an inlet channel 730that is located in an approximate center of the bottom surface of thebottom cap 726. In the depicted implementation, the recessed surface ofthe receiving chamber 630 includes an opening therethrough, and theupper frame seal 608 of the depicted implementation includes a raisedportion that is configured, when the cartridge 700 is installed in thereceiving chamber 630, of abutting against the bottom of the bottom cap726 and substantially surrounding the inlet channel 730. As such, airthat enters the gap between the cartridge 700 and the control device 600travels through the opening in the recessed surface of the receivingchamber 630 (and proximate the pressure sensor), through the raisedportion of the upper frame seal, and into the inlet channel 730 of thecartridge 700. The air that enters through the inlet channel 730 thenenters the vaporization chamber 732 of the cartridge. As the air isdrawn through the inlet channel 730 into the cartridge 700, the pressuresensor 640 of the control device 600 detects the draw. When a draw isdetected by the pressure sensor 640, the control component 614 directscurrent through the heating member 718 in order to heat the heatingmember 718. As the heating member 718 heats, at least a portion of theliquid composition contained in the liquid transport element 716 isvaporized in the vaporization chamber 732. Accordingly, aerosol producedin the vaporization chamber 732 may then directed to the user. Inparticular, as the air enters the cartridge 700 via the air inletchannel 730, the air travels through the vaporization chamber 732 whereit mixes with the vaporized liquid composition and becomes the aerosol.Due to the geometry of the vaporization chamber 732 and the bottom cap726, the aerosol is split into two separate paths that extend throughthe inside of the bottom cap 726 and then through aerosol flow tubesthat are defined on opposite sides of the reservoir cavity 728 of thetank 710. This relatively tortuous configuration may increase theeffective flow path length and area for heat sinking, thus providingincreased cooling of the aerosol stream prior to reaching the user. Thetwo aerosol paths converge at the proximal end of the tank 710 and belowthe upper aerosol channel insert 706. The recombined aerosol then flowsthrough the upper aerosol channel insert 706 and out of the exit portal715 of the mouthpiece 700, to the user.

Although other configurations are possible, in the depictedimplementation, the upper aerosol channel insert 706 is configured toabsorb liquid formed by deposition and/or condensation from aerosolformed in the vaporization chamber 732, and is configured to have rigidor semi-rigid properties. As such, the upper aerosol channel insert 706of the depicted implementation may be made of a fibrous, sinteredbeaded, or open cell foam material. For example, in someimplementations, the upper aerosol channel insert may be made of afibrous bonded polyethylene (PE) or polyethylene terephthalate (PET)material. In such a manner, the upper aerosol channel insert 706 may beconfigured for a press or snap fit attachment with the mouthpiece 702(and in particular the mouthpiece insert 704). The upper aerosol channelinsert 706 is also configured to help to prevent accumulation of liquidfrom exiting the cartridge 700 through the mouthpiece 702. In addition,the upper aerosol channel insert 706 is located in such a way thataerosol produced in the vaporization chamber 732 passes through theinsert 706 just prior to exiting the cartridge 700. In the depictedimplementation, the inside cavity of the upper aerosol channel insert706 may also serve as a cooling chamber within which the formed aerosolcan be allowed to expand and/or cool before passing through the exitportal 715. In some implementations, the vaporization chamber 732 andthe cooling chamber may be configured to have a defined relative volumeratio.

FIG. 28 illustrates an exploded perspective view of a control device ofan aerosol delivery device, according to another example implementationof the present disclosure. As shown in the figure, the control device800 of the depicted implementation generally includes a housing 802defining an outer wall 804, an upper frame 806, an upper frame seal 808,a pressure sensor seal 810, a lower frame 812, a control component 814,a battery 816, a vibration motor 818, a motor housing 820, a pin seal822, an end cap 824, a light diffuser 826, and a vent 839. The controldevice 800 of the depicted implementation also includes a front foam pad831, a plurality of side foam pads 837 (which may allow room for thebattery to expand during use), a battery insulator 839, and anelectrical insulator 847. In the depicted implementation, the batteryinsulator 839 is configured to be disposed between the battery 816 andthe control component 814, the side foam pads 837 are configured to bedisposed on opposite sides of the battery 816, the front foam pad 831 isconfigured to be disposed between the control component 841 and thehousing 804, and the electrical insulator 847 is configured to serve aninsulator for solder points when the motor and the control componentmeet. In various implementations, any one or any combination of thesecomponents need not be included. In addition, in various implementationsone or more of these components may be replaced with curing sealant,potting, tape, etc. In some implementations, the control device mayinclude one or more other seals, which may include, for example, anupper chassis seal and/or a lower chassis seal.

The arrangement of the components of the control device 800 isillustrated in FIG. 29 , which depicts a section view of the controldevice, according to an example implementation of the presentdisclosure. In particular, FIG. 29 illustrates a front section view ofthe control device 800. As illustrated in the figure, the upper frame806 of the control device 800 defines a cartridge receiving chamber 830within which a cartridge may be coupled. In the depicted implementation,the upper frame 806 and the housing 802 represent different parts;however, in other implementations, the upper frame and the housing maybe continuously formed such that they comprise the same part.

In the depicted implementation, the housing 802 comprises a metalmaterial, such as, for example, aluminum; however, in otherimplementations the housing may comprise a metal alloy material, and instill other implementations the housing may comprise a molded polymermaterial. In the depicted implementation, one or more of the upper frame806, lower frame 812, and end cap 824 may be made of a molded polymermaterial, such as, for example, a molded plastic material (e.g.,polybutylene terephthalate (PBT), acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof). In other implementations, oneor more of these components may be made of other materials, including,for example, metal materials (e.g., aluminum, stainless steel, metalalloys, etc.), glass materials, ceramic materials (e.g., alumina,silica, mullite, silicon carbide, silicon nitride, aluminum nitride,etc.), composite materials, and/or any combinations thereof.

In the depicted implementation, the lower frame 812 is configured tocontain the battery 816 in an interior area thereof. In the depictedimplementation, the battery may comprise a lithium polymer (LiPo)battery; however various other batteries may be suitable. Some otherexamples of batteries that can be used according to the disclosure aredescribed in U.S. Pat. App. Pub. No. 2010/0028766 to Peckerar et al.,the disclosure of which is incorporated herein by reference in itsentirety. In some implementations, other types of power sources may beutilized. For example, in various implementations a power source maycomprise a replaceable battery or a rechargeable battery, solid-statebattery, thin-film solid-state battery, rechargeable supercapacitor orthe like, and thus may be combined with any type of rechargingtechnology, including connection to a wall charger, connection to a carcharger (e.g., cigarette lighter receptacle, USB port, etc.), connectionto a computer, such as through a universal serial bus (USB) cable orconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a USBconnector (e.g., USB 2.0, 3.0, 3.1, USB Type-C as may be implemented ina wall outlet, electronic device, vehicle, etc.), connection to aphotovoltaic cell (sometimes referred to as a solar cell) or solar panelof solar cells, a wireless charger, such as a charger that usesinductive wireless charging (including for example, wireless chargingaccording to the Qi wireless charging standard from the Wireless PowerConsortium (WPC)), or a wireless radio frequency (RF) based charger, andconnection to an array of external cell(s) such as a power bank tocharge a device via a USB connector or a wireless charger. An example ofan inductive wireless charging system is described in U.S. Pat. App.Pub. No. 2017/0112196 to Sur et al., which is incorporated herein byreference in its entirety. In further implementations, a power sourcemay also comprise a capacitor. Capacitors are capable of dischargingmore quickly than batteries and can be charged between puffs, allowingthe battery to discharge into the capacitor at a lower rate than if itwere used to power the heating member directly. For example, asupercapacitor - e.g., an electric double-layer capacitor (EDLC) - maybe used separate from or in combination with a battery. When used alone,the supercapacitor may be recharged before each use of the article.Thus, the device may also include a charger component that can beattached to the smoking article between uses to replenish thesupercapacitor. Examples of power supplies that include supercapacitorsare described in U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al.,which is incorporated herein by reference in its entirety.

The control device 800 of the depicted implementation includes a controlmechanism in the form of the control component 814, which is configured,in part, to control the amount of electric power provided to the heatingmember of the cartridge. Although other configurations are possible, thecontrol component 814 of the depicted implementation comprises a circuitboard 834 (e.g., a printed circuit board (PCB)) that includes both rigidand flexible portions. In particular, the circuit board 834 of thedepicted implementation includes a rigid central section 815 and tworigid end sections comprising a proximal end section 817 and a distalend section 819, with each of the end sections 817, 819 being connectedto the central section 815 by a respective flexible connection. In sucha manner, when the lower frame 812, battery 816, and circuit board 834are assembled into the control device 800, the central section 815 ofthe circuit board 834 is configured to be disposed proximate a majorsurface of the battery 816, and the two end sections 817, 819 areconfigured to be disposed substantially perpendicular to the centralsection 815. In particular, the proximal end section 817 of the circuitboard 834 is configured to extend over the top of the lower frame 812,and the distal end section 819 is configured to extend over the bottomof the lower frame 812. The lower frame 812 of the control device 800 isalso configured to contain the motor housing 820, into which thevibration motor 818 is received. In various implementations, thevibration motor 818 may provide haptic feedback relating to variousoperations of the device.

The central section 815 of the depicted implementation also includes anindicator in the form of a light source 821. In some implementations,the light source may comprise, for example, at least one light emittingdiode (LED) capable of providing one or more colors of light. In otherimplementations, the light source may be configured to illuminate inonly one color, while in other implementations, the light source may beconfigured to illuminate in variety of different colors. In still otherimplementations, the light source may be configured to provide whitelight. In the depicted implementation, the light source 821 comprises anRGB (red, green, blue) LED that is configured to provide a variety ofcolors of light, including white light. The central section 815 of thedepicted circuit board 834 also includes electrical contacts 823 thatare configured to operatively connect the circuit board 834 to thevibration motor 818. Other types of electronic components, structuresand configurations thereof, features thereof, and general methods ofoperation thereof, are described in U.S. Pat. Nos. 4,735,217 to Gerth etal.; 4,947,874 to Brooks et al.; 5,372,148 to McCafferty et al.;6,040,560 to Fleischhauer et al.; 7,040,314 to Nguyen et al. and8,205,622 to Pan; U.S. Pat. App. Pub. Nos. 2009/0230117 to Fernando etal., 2014/0060554 to Collet et al., and 2014/0270727 to Ampolini et al.;and U.S. Pat. App. Pub. No. 2015/0257445 to Henry et al.; which areincorporated herein by reference. Yet other features, controls orcomponents that can be incorporated into aerosol delivery devices of thepresent disclosure are described in U.S. Pat. Nos. 5,967,148 to Harriset al.; 5,934,289 to Watkins et al.; U.S. Pat. No. 5,954,979 to Countset al.; 6,040,560 to Fleischhauer et al.; 8,365,742 to Hon; 8,402,976 toFernando et al.; U.S. Pat. App. Pub. Nos. 2010/0163063 to Fernando etal.; 2013/0192623 to Tucker et al.; 2013/0298905 to Leven et al.;2013/0180553 to Kim et al., 2014/0000638 to Sebastian et al.,2014/0261495 to Novak et al., and 2014/0261408 to DePiano et al.; whichare incorporated herein by reference in their entireties.

In the depicted implementation, the vent 845 is configured to beinstalled on the inside of the housing 802 such that it covers theaperture 825. As such, in the depicted implementation one side of thevent 845 may include a pressure sensitive adhesive. In the depictedimplementation, the vent 845 comprises a breathable membrane material,such as, for example, a Gore-Tex® material; however, other suitablematerials are possible. In the depicted implementation, the light source821 is covered by the light diffuser 826, a portion of which isconfigured to be received by the end cap 824. In the depictedimplementation, the light diffuser forms a press-fit connection with theend cap 824; however, in other implementations, the light diffuser maybe affixed to the end cap in another manner. When assembled, the lightdiffuser 826 is positioned in or proximate an aperture 825 defined inthe outer wall 804 of the housing 802 and proximate a distal endthereof. In the depicted implementation, the aperture 825 comprises anarrow, elongate opening; however, in other implementations, theaperture may be provided in any desired shape and may be positioned atany location on the control device 800. In some implementations, thelight diffuser 826 may comprise a transparent or translucent memberconfigured to allow a user to view the light source 821 from the outsideof the housing 802. In the depicted implementation, the light diffuser826 may be made of a molded polymer material, such as, for example, amolded plastic material (e.g., polybutylene terephthalate (PBT),acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof), although other materials, including glass, arepossible. In various implementations, further indicators (e.g., otherhaptic feedback components, an audio feedback component, or the like)can be included in addition to or as an alternative to the indicatorsincluded in the depicted implementation. Additional representative typesof components that yield visual cues or indicators, such as LEDcomponents, and the configurations and uses thereof, are described inU.S. Pat. Nos. 5,154,192 to Sprinkel et al.; 8,499,766 to Newton and8,539,959 to Scatterday; U.S. Pat. App. Pub. No. 2015/0020825 toGalloway et al.; and U.S. Pat. App. Pub. No. 2015/0216233 to Sears etal.; which are incorporated herein by reference in their entireties.

Although other configurations are possible, the proximal end section 817of the circuit board 834 of the depicted implementation includes a pairof conductive pins 836A, 836B, as well as a pressure sensor 840. In thedepicted implementation, the conductive pins 836A, 836B comprisespring-loaded pins (e.g., electrical pogo pins) that extend through theupper frame 806 such that portions of the ends of the pins 836A, 836Bextend into the cartridge receiving chamber 830 and are biased in thatposition due to the force of the internal springs of the conductive pins836A, 636B. In such a manner, when a cartridge is coupled with thecontrol device 800, the conductive pins 836A, 836B are configured tocontact corresponding features of the cartridge and deflect downward(e.g., toward the lower frame 812) against the force of the springs,thus operatively connecting the installed cartridge with the controlcomponent 814 and the battery 816. In the depicted implementation, theconductive pins 836A, 836B comprise gold plated metal pins; however,other materials or combinations of materials, which may also includecoatings and/or platings of electrically conductive materials, arepossible. Examples of electrically conductive materials, include, butare not limited to, copper, aluminum, platinum, gold, silver, iron,steel, brass, bronze, graphite, conductive ceramic materials, and/or anycombination thereof. Although other profiles are possible, the ends ofthe conductive pins 836A, 836B of the depicted implementation have arounded profile such that deflection of the conductive pins 836A, 836Bis facilitated when a cartridge is inserted into the cartridge receivingchamber 830. In other implementations, the conductive pins may bepositioned in other locations of the cartridge receiving chamber 830,such as, for example, proximate the top of the cartridge receivingchamber 830. In other implementations, the conductive pins may bepositioned at a point on the sides of the upper frame between theproximal end of the outer housing and the bottom wall of the upperframe. Further, in still other implementations the conductive pins maybe positioned between a midpoint of the sidewalls and the proximal endof the outer housing (i.e., in an upper half of the sidewalls).Alternatively, the conductive pins may be positioned between a midpointof the sidewalls and the bottom wall of the inner frame wall (e.g., in alower half of the sidewalls). Moreover, in still other implementations,the conductive pins may be present at any position of the upper frame.

In various implementations, the aerosol delivery device may include anairflow sensor, pressure sensor, or the like. As noted above, thecontrol component 814 of the depicted implementation includes a pressuresensor 840, which is positioned proximate and below the cartridgereceiving chamber 830. The position and function of the pressure sensor840 of the depicted implementation will be described below; however, inother implementations an airflow or pressure sensor may be positionedanywhere within the control device 800 so as to subject to airflowand/or a pressure change that can signal a draw on the device and thuscause the battery 816 to delivery power to the heating member of acartridge. Various configurations of a printed circuit board and apressure sensor, for example, are described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., the disclosure of which is incorporatedherein by reference in its entirety. In the absence of an airflowsensor, pressure sensor, or the like, an aerosol delivery device may beactivated manually, such as via a pushbutton that may be located on thecontrol device and/or the cartridge. For example, one or morepushbuttons may be used as described in U.S. Pat. App. Pub. No.2015/0245658 to Worm et al., which is incorporated herein by referencein its entirety. Likewise, a touchscreen may be used as described inU.S. Pat. App. Ser. No. 14/643,626, filed Mar. 10, 2015, to Sears etal., which is incorporated herein by reference in its entirety. As afurther example, components adapted for gesture recognition based onspecified movements of the aerosol delivery device may be used as aninput. See U.S. Pat. App. Pub. 2016/0158782 to Henry et al., which isincorporated herein by reference in its entirety.

Although not included in the depicted implementation, someimplementations may include other types of input elements, which mayreplace or supplement an airflow or pressure sensor. The input may beincluded to allow a user to control functions of the device and/or foroutput of information to a user. Any component or combination ofcomponents may be utilized as an input for controlling the function ofthe device. In some implementations, an input may comprise a computer orcomputing device, such as a smartphone or tablet. In particular, theaerosol delivery device may be wired to the computer or other device,such as via use of a USB cord or similar protocol. The aerosol deliverydevice may also communicate with a computer or other device acting as aninput via wireless communication. See, for example, the systems andmethods for controlling a device via a read request as described in U.S.Pat. App. Pub. No. 2016/0007561 to Ampolini et al., the disclosure ofwhich is incorporated herein by reference in its entirety. In suchembodiments, an APP or other computer program may be used in connectionwith a computer or other computing device to input control instructionsto the aerosol delivery device, such control instructions including, forexample, the ability to form an aerosol of specific composition bychoosing the nicotine content and/or content of further flavors to beincluded. Additional representative types of sensing or detectionmechanisms, structure and configuration thereof, components thereof, andgeneral methods of operation thereof, are described in U.S. Pat. Nos.5,261,424 to Sprinkel, Jr.; 5,372,148 to McCafferty et al.; and PCT WO2010/003480 to Flick; which are incorporated herein by reference intheir entireties.

In the depicted implementation, the pressure sensor seal 810 isconfigured to cover the pressure sensor 840 to protect it from anyliquid and/or aerosol from an installed cartridge. In such a manner, thepressure sensor seal 810 of the depicted implementation, as well asother sealing members, including, for example, the upper frame seal 808(and/or cartridge intake seal 850), the motor housing 820, the pin seal822 (and/or the end cap seal 843), may be made of silicone rubber, boronnitride (BN) rubber, natural rubber, thermoplastic polyurethane, oranother resilient material. In some implementations, the upper portionsof the end cap pins are configured to engage with the lower frame. Forexample, in some implementations the upper portions of the end cap pinsare configured to create an interference or press-fit engagement withcorresponding slotted openings in the lower frame. In variousimplementations, the interface between the end cap and the housing(e.g., via the interface between the end cap seal and the inner surfaceof the outer housing wall and/or the upper portions of the end cap pinsand the lower frame) may create a press-fit engagement with the housingthat is configured to be releasable so that the end cap (or end capassembly) may be removable. In some implementations the control devicemay include one or more components configured to meet battery outgassingrequirements under UL 8139. For example, the control device may includean end cap configured to eject in the event that sudden pressurizationoccurs within the control device enclosure. In one implementation, theend cap may include retaining pins that extend substantiallyperpendicularly from a wall of the end cap. The retaining pins may beconfigured to mate with receiving features (e.g., holes) in a frame ofthe control device to establish a friction fit or press fit that may beovercome if an internal pressure within the control device housingexceeds a defined internal pressure.

Although other configurations are possible, the distal end section 819of the circuit board 834 includes the external connection element 838.In various implementations, the external connection element 838 may beconfigured for connecting to an external connector and/or a dockingstation or other power or data source. For example, in someimplementations an external connector may comprise first and secondconnector ends that may be interconnected by a union, which may be, forexample, a cord of variable length. In some implementations, the firstconnector end may be configured for electrical and, optionally,mechanical connection with the device, and the second connector end maybe configured for connection to a computer or similar electronic deviceor for connection to a power source. An adaptor including a USBconnector at one end and a power unit connector at an opposing end isdisclosed in U.S. Pat. App. Pub. No. 2014/0261495 to Novak et al., whichis incorporated herein by reference in its entirety. In the depictedimplementation, the pin seal 822 is configured to seal the interfacebetween the external connection element 838 and the end cap 824. In thedepicted implementation, one or more pins of the external connectionelement 838 may extend through the end cap 824 of the control device asnoted above. In the depicted implementation, the end cap 824 alsoincludes a pair of end cap pins 841A, 841B that may be affixed to theend cap 824. For example, in some implementations, the end cap pins841A, 641B may be insert-molded into the end cap 824. In someimplementations, a bottom surface of the end cap pins 841A, 841B (which,in some implementations, may be flat) may be configured to provideattraction for magnets contained in an external charger assembly. Insuch a manner, the end cap pins 841A, 841B may be made of any materialconfigured to be attracted by a magnet, such as various ferromagneticmaterials, including, but not limited, to steel, iron, nickel, cobalt,other alloys, and/or any combination thereof. In the depictedimplementation, the opposite ends of the end cap pins 841A, 841B havemultiple diameter sections. For example, each of the pins 841A, 841Bdefines at least three sections above the end cap 824, a first sectionproximate the end cap 824, a second section above the first section, andend section distal from the end cap 824. In the depicted implementation,the end sections of the pins 841A, 841B have an angled diameter, and thefirst section has an outer diameter larger than that of the secondsection.

The upper frame 806 of the depicted implementation includes a pair ofmagnets 846A, 846B that are exposed in the cartridge receiving chamber830. In various implementations, the magnets 846A, 846B may comprise anytype of magnets, including rare earth magnets. For example, in someimplementations, one or more of the magnets may comprise Neodymiummagnets (also known as NdFeB, NIB, or Neo magnets). In variousimplementations, different grades of Neodymium magnets may be used,including, for example, N35, N38, N40, N42, N45, N48, N50, and/or N52grades. In other implementations, one or more of the magnets maycomprise Samarium Cobalt magnets (also known as SmCo magnets). In stillother implementations, one or more of the magnets may compriseCeramic/Ferrite magnets. In other implementations, one or more of themagnets may comprise Aluminum-Nickel-Cobalt (AlNiCo) magnets. In any ofthe foregoing implementations, one or more of the magnets may be platedand/or coated. For example, in some implementations, one or more of themagnets may be coated with nickel. In other implementations, one or moremagnets may be coated with one or more of zinc, tin, copper, epoxy,silver and/or gold. In some implementations, one or more of the magnetsmay be coated with combinations of these materials. For example, in oneimplementation, one or more of the magnets may be coated with nickel,copper, and nickel again. In another implementation, one or more of themagnets may be coated with nickel, copper, nickel, and a top coating ofgold.

FIG. 30 illustrates a perspective partial section view of a controldevice of an aerosol delivery device. In particular, FIG. 30 illustratesa partial section view of the housing 802, upper frame 806, upper frameseal 808, pressure sensor seal 810, pressure sensor 840, cartridgeintake seal 850, and lower frame 812 of the control device 800. In thedepicted implementation, the cartridge intake seal 850 forms anoutwardly extending radial profile (e.g., a suction cup-like profile)that extends above (e.g., toward/into the receiving chamber 830) therecessed surface 844 of the receiving chamber 830. In the depictedimplementation, the cartridge intake seal 850 is part of the sameovermold that includes the upper frame seal 808 (and thus may be made ofthe same material); however, in other implementations these seals mayform separate parts, which may or may not be the result of anovermolding process. As shown in the figure, a portion of the conductivepins 836A, 836B of the control component 814 extend through the upperframe 806 and a portion of the cartridge intake seal 850. In particular,a portion of the conductive pins 836A, 836B of the depictedimplementation, which as noted above comprise spring-loaded contacts,extend through a recessed surface 844 and a portion of the cartridgeintake seal 850 of the upper frame 806 and into the cartridge receivingchamber 830.

As also shown in the figure, the upper frame 806 includes a pair ofmagnets 846A, 846B that are also exposed in the cartridge receivingchamber 830. In various implementations, the magnets 846A, 846B maycomprise any type of magnets, including rare earth magnets. For example,in some implementations, one or more of the magnets may compriseNeodymium magnets (also known as NdFeB, NIB, or Neo magnets). In variousimplementations, different grades of Neodymium magnets may be used,including, for example, N35, N38, N40, N42, N45, N48, N50, and/or N52grades. In other implementations, one or more of the magnets maycomprise Samarium Cobalt magnets (also known as SmCo magnets). In stillother implementations, one or more of the magnets may compriseCeramic/Ferrite magnets. In other implementations, one or more of themagnets may comprise Aluminum-Nickel-Cobalt (AlNiCo) magnets. In any ofthe foregoing implementations, one or more of the magnets may be platedand/or coated. For example, in some implementations, one or more of themagnets may be coated with nickel. In other implementations, one or moremagnets may be coated with one or more of zinc, tin, copper, epoxy,silver and/or gold. In some implementations, one or more of the magnetsmay be coated with combinations of these materials. For example, in oneimplementation, one or more of the magnets may be coated with nickel,copper, and nickel again. In another implementation, one or more of themagnets may be coated with nickel, copper, nickel, and a top coating ofgold.

In the depicted implementation, each magnet 846A, 846B is substantiallysurrounded by a respective location feature 848A, 848B of the upperframe 806, wherein the location features 848A, 848B also extend into thecartridge receiving chamber 830. As will be discussed in more detailbelow, one or more of the location features 848A, 848B of the upperframe 806 are configured as stopping or vertical locating features foran installed cartridge and are thus configured to position the cartridgewith respect to the recessed surface 844 of the upper frame 806 of thecontrol device 800. In the depicted implementation, the recessed surface844 of the upper frame 806 also defines an air intake opening 852, whichextends through the upper frame 806 and proximate the pressure sensorseal 810. In the depicted implementation, the air intake opening 852 isconfigured to receive air drawn into the aerosol delivery device by auser (see FIG. 35 ).

As noted above, a portion of the cartridge is configured to be coupledwith the cartridge receiving chamber 830 of the inner frame 806 of thecontrol device 800 such that mechanical and electrical connections arecreated between the cartridge and the control device 800. In particular,when as cartridge is coupled with the upper frame 806 of the controldevice 800, a magnetic connection is created between the magnets 846A,846B located in the upper frame 806 and corresponding features of thecartridge, and an electrical connection is created between the pairconductive pins 836A, 236B of the control device 800 and correspondingfeatures of the cartridge. As such, when a cartridge is received in thereceiving chamber 830 of the control device 800, the cartridge may beoperatively connected to the control component 814 and the battery 816of the control device 800. In addition, the outwardly angled profile ofthe cartridge intake seal 850 deflects downward thus forming asubstantially air tight seal with the bottom of the cartridge, and inparticular, around the air inlet channel of a cartridge. Thus, when acartridge is coupled with the control device, the cartridge ismechanically biased into connection with the control device such thatelectrical connection is maintained between the cartridge and thecontrol device and a seal is formed between the cartridge and thecontrol device. It should be understood that for the purposes of thepresent disclosure, the term “operatively connected” and other relatedforms thereof should be interpreted broadly so as to encompasscomponents that are directly connected and/or connected via one or moreadditional components.

FIG. 31 illustrates a perspective view of an end cap assembly, accordingto an example implementation of the present disclosure. In particular,FIG. 31 illustrates a perspective view of the end cap 824, lightdiffuser 826, and end cap pins 841A, 841B. As shown in the figure, theend cap 824 also includes an end cap seal 843 that provides a sealinginterface between the end cap 824 and the housing 802, and inparticular, an inner surface of the outer wall 804. The depictedimplementation also includes a pin seal 822, which is configured to sealthe interface between the external connection element and the end cap.In the depicted implementation, the pin seal 822 and the end cap seal843 comprise a single overmolded part; however, in other implementationsthese parts may be separate. In various implementations, the end capseal 843 and/or pin seal 822 may be made of silicone rubber, boronnitride (BN) rubber, natural rubber, thermoplastic polyurethane, oranother resilient material. As also shown in FIG. 29 , in variousimplementations the upper portions of the end cap pins 841A, 841B may beconfigured to engage with the lower frame 812. For example, in thedepicted implementation the upper portions of the end cap pins 841A,841B are configured to create a sliding or an interference or press-fitengagement with corresponding slotted openings in the lower frame 812.In various implementations, the interface between the end cap 824 andthe housing 802 (e.g., via the interface between the end cap seal 843and the inner surface of the outer housing wall 804 and/or the upperportions of the end cap pins 841A, 841B and the lower frame 812) maycreate a press-fit engagement with the housing 802 that is configured tobe releasable so that the end cap 824 (or end cap assembly) may beremovable.

In various implementations, the control device may include one or morecomponents configured to meet battery outgassing requirements under UL8139. For example, the control device may include an end cap configuredto eject in the event that sudden pressurization occurs within thecontrol device enclosure. In one implementation, the end cap may includeretaining pins that extend substantially perpendicularly from a wall ofthe end cap. The retaining pins may be configured to mate with receivingfeatures (e.g., holes) in a frame of the control device to establish afriction fit or press fit that may be overcome if an internal pressurewithin the control device housing exceeds a defined internal pressure.

FIGS. 32, 33, and 34 illustrate a cartridge according to another exampleimplementation of the present disclosure. In particular, FIG. 32illustrates an exploded perspective view of a cartridge 900, FIG. 33illustrates a front section view of the cartridge 900, and FIG. 34illustrates a side section view of the cartridge 900. Although otherconfigurations are possible, the cartridge 900 of the depictedimplementation generally includes a mouthpiece 902, a mouthpiece insert904, an upper aerosol channel insert 906, an upper cartridge seal 908, atank 910 that defines a tank wall 911, a lower cartridge seal 912, abase member 914, a liquid transport element (e.g., a wick) 916, aheating member 918, a pair of heater connectors 920A, 920B, a pair ofmetal inserts 924A, 924B, and a bottom cap 926.

As shown in the figures, the mouthpiece 902 of the depictedimplementation defines a proximal end and a distal end, with theproximal end of the mouthpiece 902 defining an exit portal 915 therein.In the depicted implementation, the mouthpiece insert 904 is configuredto be located proximate the proximal end of the mouthpiece 902 such thatit extends through the exit portal 915 thereof. In the depictedimplementation, the mouthpiece 902 may be made of a moldable plasticmaterial, such as polypropylene, although other materials are possibleincluding, but not limited to, Tritan™ copolyester, acrylonitrilebutadiene styrene (ABS), polyethylene, polycarbonate, Polyamide (Nylon),high impact polystyrene, and combinations thereof. In the depictedimplementation, the mouthpiece insert 904 may be made of a moldedpolymer material, such as, for example, Tritan™ copolyester, althoughother materials are possible, including, but not limited to,polypropylene, acrylonitrile butadiene styrene (ABS), polyethylene,polycarbonate, Polyamide (Nylon), high impact polystyrene, andcombinations thereof. In the depicted implementation, the uppercartridge seal 908 is overmolded onto/with the mouthpiece insert 904,although in other implementations these components may representseparate parts. In the depicted implementation, the upper cartridge seal908 is configured to form a substantially air tight and liquid tightseal between the tank 910 and the mouthpiece 902. As such, the uppercartridge seal 908 may be made of thermoplastic elastomer. In otherimplementations, the upper cartridge seal may be made of othermaterials, including, but not limited to, silicone rubber, boron nitride(BN) rubber, natural rubber, thermoplastic polyurethane, or anotherresilient material. In the depicted implementation, the mouthpieceinsert 904 is configured to receive and seal the upper aerosol channelinsert 906.

In the depicted implementation, the mouthpiece insert 904 and uppercartridge seal 908 assembly includes a flange feature such that themouthpiece insert 904 and upper cartridge seal 908 may be installed frominside the mouthpiece 902 and may be configured for a press or snap-fitconnection with the exit portal 915 and/or another portion of themouthpiece 902. In other implementations, other attachment methods arepossible (e.g., via adhesives, heat staking/welding, ultrasonic welding,etc.). In the depicted implementation, the mouthpiece 902 is configuredto be secured to the tank 910 via snap features. For example, themouthpiece 902 of the depicted implementation includes a ridge featurethat extends around at least a portion of an inner surface thereof, andthe tank 910 includes a corresponding groove feature that extends aroundat least a portion of an outer surface thereof. In otherimplementations, these features may be reversed (e.g., the mouthpiecemay include a groove and the tank may include a ridge feature). In stillother implementations, other attachment methods are possible (e.g., viaadhesives, heat staking/welding, ultrasonic welding, etc.).

In some implementations, the mouthpiece insert may exhibit a colorassociated with a distinctive characteristic of the cartridge. Forexample, in some implementations a cartridge of the present disclosuremay include a liquid composition that includes a distinctivecharacteristic such as, for example, a particular flavorant (asdiscussed infra), or a specific strength of nicotine, although anycharacteristic of the cartridge may be considered a distinctivecharacteristic. For the purposes of the current description, the term“color” should be interpreted broadly, for example covering any color orany shade of the same color. It should also be noted that in someimplementations, certain colors may be commonly associated withparticular distinctive characteristics (e.g., the color green may beassociated with a mint flavorant, and the color red may be associatedwith an apple flavorant); however, in other implementations, certaincolors may be associated with particular distinctive characteristicsaccording to an index or guide, which may be provided or made availableto a user. Examples of distinctive characteristics are described in U.S.Pat. App. Serial No. 16/171,920, titled Aerosol Delivery Device withFlavor Indicator, which is incorporated herein by reference in itsentirety.

The tank 910 of the depicted implementation defines a proximal end and adistal end, wherein the mouthpiece 902 is configured to engage theproximal end of the tank 910 and the bottom cap 926 is configured toengage the distal end of the tank 910. In the depicted implementation,the tank 910 also defines a reservoir cavity 928 that includes a closedproximal end and an open distal end. As such, the reservoir cavity 928of the tank 910 is configured to contain a liquid composition (e.g., ane-liquid or aerosol precursor composition) therein. The closed proximalend of the reservoir cavity 928 allows the cavity to create a reliableseal on the top side of the liquid composition column. This may preventthe seepage/entry of air into the reservoir cavity from the top end whenthe cartridge is held upright. This may also prevent air from enteringfrom the top of the liquid composition column, which may create a vacuumand may reduce the potential of the liquid composition to leak from thebottom of the tank through the liquid transport element or otherpassages.

Although other configurations are possible, in the depictedimplementation a pair of internal aerosol flow tubes 933A, 933B aredefined on opposite sides of the reservoir cavity 928 of the tank 910.In the case of an injection molded tank 910, the internal aerosol flowtubes are configured to be molded therein. As will be described in moredetail below, aerosol produced in a vaporization chamber of thecartridge 900 is configured to travel through the aerosol flow tubes fordelivery to a user.

In the depicted implementation, the tank wall 911 is configured to betransparent or translucent so that the liquid composition containedtherein may be visible externally. As such, in the depictedimplementation the entire tank wall 911 is configured to be transparentor translucent. Alternatively, in some implementations, only a portionof the tank wall or only a single side of the tank wall may betransparent or translucent while the remaining portions of the tank wallmay be substantially opaque. In other implementations, the tank wall maybe substantially opaque, and a strip extending from the proximal end ofthe tank to the distal end of the tank may be transparent ortranslucent. In further implementations, the tank wall may be colored.In some implementations, the color can be configured so that the liquidcomposition within the tank is still visible, such by using atransparent or translucent outer tank wall. In other implementations,the tank wall can be configured so that the outer tank wall hassubstantially opaque color. In the depicted implementation, the tank 910is made of Tritan™ copolyester, although in other implementations thetank may be made of other materials including, but not limited to,acrylonitrile butadiene styrene (ABS), polyethylene, polycarbonate,Polyamide (Nylon), high impact polystyrene, polypropylene, andcombinations thereof. Still other materials are possible, including, forexample, glass.

For those implementations that include an indication window in thecontrol device, at least a portion of the tank and/or at least a portionof the bottom cap may be visible when the cartridge is engaged with thecontrol device. As noted above, in some implementations at least aportion of the tank wall 911 may be configured to be at least partiallytransparent or translucent so that the liquid composition containedtherein is visible externally. Thus, in some implementations therelative amount of any liquid composition present in the tank may bevisible through the indication window when the cartridge is engaged withthe control device. In some implementations, the indication window maybe located near the proximal end of the control device and is configuredas an elongate oval shaped cut-out in the outer wall of the housing andthe upper frame of the control device. It should be understood that instill other implementations, the indication window may have any othershapes and/or locations, as described above with respect to otherdepicted implementations, and, as noted, some implementations need notinclude any indication windows.

In the depicted implementation, the tank 910, and in particular, thereservoir cavity 928, contains a liquid composition, which may includean aerosol precursor composition and/or a flavorant. Reference is madeto the above discussions of these materials and variations thereof. Asshown in the figures, the cartridge 900 of the depicted implementationalso includes a base member 914, which is configured to engage and coverthe open distal end of the reservoir cavity 928 of the tank 910. In thedepicted implementation, the lower cartridge seal 912 is overmoldedonto/with the mouthpiece insert 904, although in other implementationsthese components may represent separate parts. The lower cartridge seal912 of the depicted implementation is configured form a substantiallyair tight and liquid tight seal between a lower portion of the tank 910and the bottom cap 926. In the depicted implementation, the lowercartridge seal 912 is made of silicon rubber. In other implementations,the lower seal may be made of other materials, including, but notlimited to, boron nitride (BN) rubber, natural rubber, thermoplasticpolyurethane, or another resilient material. In the depictedimplementation, the base member 914 is made of Tritan™ copolyester. Inother implementations, the base member may be made of another material,including, but not limited to, acrylonitrile butadiene styrene (ABS),polyethylene, polycarbonate, Polyamide (Nylon), high impact polystyrene,polypropylene, and combinations thereof. The base member 914 of thedepicted implementation may also include a plurality of slots that areconfigured to provide liquid flow passages for the liquid compositioncontained in the reservoir cavity 928 of the tank 910 in order tofacilitate transfer of the liquid to the liquid transport element 716.In some implementations, the slots may also provide retention of someliquid even when the bulk liquid composition in the reservoir cavity 928is not in contact with the base member 914 (such as, for example, whenthe aerosol delivery device is upside down).

As shown in the figures, the liquid transport element 916 is disposedwithin the base member 914 and extends between the liquid composition inthe reservoir cavity 928 and the heating member 918. In the depictedimplementation, the liquid transport element 916 is made of 100% cottonand, when installed in the cartridge 900, has a curved shape. In otherimplementations, however, the liquid transport element may have othershapes and may be formed of a variety of materials configured fortransport of a liquid, such as by capillary action. For example, in someimplementations the liquid transport element may be formed of fibrousmaterials (e.g., organic cotton, cellulose acetate, regeneratedcellulose fabrics, glass fibers), porous ceramics, porous carbon,graphite, porous glass, sintered glass beads, sintered ceramic beads,capillary tubes, or the like. In other implementations, the liquidtransport element may be any material that contains an open pore network(i.e., a plurality of pores that are interconnected so that fluid mayflow from one pore to another in a plurality of direction through theelement). As further discussed herein, some implementations of thepresent disclosure may particularly relate to the use of non-fibroustransport elements. As such, fibrous transport elements may be expresslyexcluded. Alternatively, combinations of fibrous transport elements andnon-fibrous transport elements may be utilized. Representative types ofsubstrates, reservoirs or other components for supporting the aerosolprecursor are described in U.S. Pat. No. 8,528,569 to Newton; U.S. Pat.App. Pub. Nos. 2014/0261487 to Chapman et al. and 2014/0059780 to Daviset al.; and U.S. Pat. App. Pub. No. 2015/0216232 to Bless et al.; whichare incorporated herein by reference in their entireties. Additionally,various wicking materials, and the configuration and operation of thosewicking materials within certain types of electronic cigarettes, are setforth in U.S. Pat. No. 8,910,640 to Sears et al.; which is incorporatedherein by reference in its entirety. In some implementations, the liquidtransport element may be formed partially or completely from a porousmonolith, such as a porous ceramic, a porous glass, or the like. Examplemonolithic materials suitable for use according to embodiments of thepresent disclosure are described, for example, in U.S. Pat. App. SerialNo. 14/988,109, filed Jan. 5, 2016, and US Pat. No. 2014/0123989 toLaMothe, the disclosures of which are incorporated herein by referencein their entireties.

As shown in the figures, the heating member 918 of the depictedimplementation is also configured to be disposed within the base member914. In particular, the heating member 918 of the depictedimplementation comprises a heating element that has a substantially flatprofile. While in some implementations the heating member may maintain asubstantially flat profile when installed in a cartridge, when theheating member 918 of the depicted implementation is installed in thecartridge 900 it has a curved or bowed shape corresponding to the curvedshape of the liquid transport element 916. Although otherimplementations may differ, in the depicted implementation the heatingmember 918 includes a first end, a second end, and a heater loopconnecting the first end and the second end. In particular, the heaterloop of the depicted implementation comprises a serpentine pattern ofheater traces that are connected at respective ends thereof and thatextend substantially transverse to a longitudinal axis of the heatingmember to connect the first end to the second end. While in someimplementations the heater traces may be solid, the heater traces of thedepicted implementation comprise a plurality of split traces. In thedepicted implementation, the edges of the heating member aresubstantially solid and the plurality of split traces are located in acentral area of the heating member. In such a manner, the heater loop ofthe depicted implementation may be configured to concentrate heat in anarea of the heating element configured to be in contact with the liquidtransport element 916.

In the depicted implementation, the heating member 918 in the installedposition contacts a bottom surface of the liquid transport element 916.In the depicted implementation, the curved form of the flat heatingmember 918 may provide a large ratio of cross-sectional flow area toflow path length through the liquid transport element 916. This mayprovide increased performance with respect to delivery of the liquidcomposition to the liquid transport element 916. When installed, edgesof the heating member 918 are configured to engage the base member 914such that the heating member 918 maintains its curved shape. In such amanner, the curvature of the heating member 918 may also provide acompressive force against the liquid transport element 916. In addition,the spring recover force of the heating member 918 allows the edges ofthe heating member 918 to locate or lock into the base member 914, whichmay reduce or eliminate any need for additional features configured tohold the heating member 918 in the base member 914 from the other side.The installed curvature of the heating member 918 may also biasdeflection of the heating member 918 that may occur with thermalexpansion towards the liquid transport element 916, thus helping tomaintain thermal contact between the heating member 918 and the liquidtransport element 916. In the depicted implementation, the liquidtransport element 916 and the heating member 918 comprise a heatingassembly 934, which, together with the base member 914 and a nozzlemember 955, define a vaporization chamber 932. In the depictedimplementation, the nozzle member 955 includes a central opening and islocated proximate the base member 926 and below the heating member 918.In the depicted implementation, the nozzle member 955 is made ofsilicone rubber although other materials are possible, including, butnot limited to, boron nitride (BN) rubber, natural rubber, thermoplasticpolyurethane, or another resilient material. In the depictedimplementation, the nozzle member 955 is also configured to act as aheat shield to protect the base member 926 from radiant heat from theheating member 918. It may also create an indirect air inlet flow path,block direct line of sight to the heating member 918 from outside of thecartridge 900, and/or help prevent aerosol particles from exitingthrough the air inlet channel 930. In other implementations, the nozzlemember may be made of other materials, including, but not limited to,moldable plastic materials.

It should be noted that some implementations need not include a heatingassembly, but, rather, may include an atomization assembly configured togenerate an aerosol in another manner. Some examples of atomizationassemblies that generate aerosols in other ways can be found, forexample, in U.S. App. No. 16/544,326, filed on Aug. 19, 2019, and titledDetachable Atomization Assembly for Aerosol Delivery Device, which isincorporated herein by reference in its entirety.

In the depicted implementation, the heating member 918 is made of 316Lstainless steel, although other materials may be used including, but notlimited to, 316, 304, or 304L stainless steel. In other implementations,the heating member may be made of a different material, such as, forexample, Kanthal (FeCrAl), Nichrome, Molybdenum disilicide (MoSi₂),molybdenum silicide (MoSi), Molybdenum disilicide doped with Aluminum(Mo(Si,Al)₂), titanium, platinum, silver, palladium, alloys of silverand palladium, graphite and graphite-based materials (e.g., carbon-basedfoams and yarns). In further implementations, the heating member may beformed from conductive inks, boron doped silica, and/or ceramics (e.g.,positive or negative temperature coefficient ceramics). Other types ofheaters may also be utilized, such as laser diodes or microheaters. Alaser diode can be configured to deliver electromagnetic radiation at aspecific wavelength or band of wavelengths that can be tuned forvaporization of the aerosol precursor composition and/or tuned forheating a liquid transport element via which the aerosol precursorcomposition may be provided for vaporization. The laser diode canparticularly be positioned so as to deliver the electromagneticradiation within a chamber, and the chamber may be configured to beradiation-trapping (e.g., a black body or a white body). Suitablemicroheaters are described in U.S. Pat. No. 8,881,737 to Collett et al.,which is incorporated herein by reference in its entirety. Microheaters,for example, can comprise a substrate (e.g., quartz, silica) with aheater trace thereon (e.g., a resistive element such as Ag, Pd, Ti, Pt,Pt/Ti, boron-doped silicon, or other metals or metal alloys), which maybe printed or otherwise applied to the substrate. A passivating layer(e.g., aluminum oxide or silica) may be provided over the heater trace.Other heaters are described in U.S. Pat. App. Pub. No. 2016/0345633 toDePiano et al., which is incorporated herein by reference in itsentirety.

Although in other implementations additional and/or differing contactfeatures may be provided, the heating member 918 of the depictedimplementation includes a pair of contact holes that are configured toconnect the heating member 918 to the heater connectors 920A, 920B ofthe cartridge 900. In depicted implementation, the heater connectors920A, 920B are made of brass and are plated with gold over nickel. Inother implementations, the heater connectors may be made of anotherconductive material that may or may not be plated. Examples of otherpossible conductive materials include, but are not limited to, copper,aluminum, platinum, gold, silver, iron, steel, bronze, graphite,conductive ceramic materials, and/or any combination thereof. In thedepicted implementation, the heater connectors 920A, 920B areinsert-molded into the bottom cap 926. Although other configurations arepossible, in the depicted implementation the bottom surfaces of theheater connectors 920A, 920B are recessed with respect to the bottomsurface of the bottom cap 926.

The bottom cap 926 of the depicted implementation is configured to besecured to the distal end of the tank 910 via an ultrasonic weldingprocess; however, other attachment methods are possible (e.g., viaadhesives, heat staking/welding, snap-fit, etc.). In the depictedimplementation, the bottom cap 926 of the cartridge 900 includes acartridge air inlet channel 930, which is located in an approximatecenter of a bottom surface of the bottom cap 926. Although otherconfigurations are possible, in the depicted implementation thecartridge air inlet channel 930 has an oval shape and includes across-bar feature that extends across the inlet between the opening ofthe air inlet channel 930 and the vaporization chamber 932.

Although other configurations are possible, the cartridge 900 of thedepicted implementation also includes a pair of metal inserts 924A, 924Bthat are positioned in the bottom cap 926 and are configured to beexposed through the bottom surface thereof. In the depictedimplementation, the metal inserts 924A, 924B are insert-molded into thebottom cap 926. In some implementations, the metal inserts may beconfigured for a press or snap fit connection with the bottom cap. Inthe depicted implementation, the metal inserts 924A, 924B are made ofstainless steel plated with nickel; however, in other implementationsthe metal inserts may be made of any material configured to be attractedby a magnet, such as various ferromagnetic materials, including, but notlimited, to iron, nickel, cobalt, alloys such as steel, and/or anycombination thereof.

Airflow into a control device of one example implementation of thepresent disclosure is illustrated in FIG. 35 . In particular, FIG. 35illustrates a side section view of a control device 800. As air is drawninto the control device 800 through a gap between an installed cartridgeand the control device 800 as described above (such as, for example,between the cartridge and the top of the outer wall 804 of the housing802 and/or between the cartridge and the upper frame 806), the air isdrawn downward toward the bottom of the receiving chamber 830, whereinit enters the air intake opening 852. It should be noted that in variousimplementations, changes in the size and/or shape of the air intakeopening and/or the gap between the cartridge and the control device mayaffect resistance to draw; thus, one or more of the related componentsmay be designed to create a desired resistance. In the depictedimplementation, air that enters the air intake opening 852 flows abovethe pressure sensor seal 810 (and pressure sensor 840) where it isdirected into the cartridge through the upper frame 806, and cartridgeintake seal 850 thereof.

Air and aerosol flow through a cartridge of one example implementationis illustrated in FIGS. 36, 37, and 38 . In particular, FIG. 36illustrates an angled side section view of a cartridge 900 showing airand aerosol flow; FIG. 37 illustrates an angled front section view ofthe cartridge 900; and FIG. 38 illustrates a bottom perspective view ofthe cartridge 900. As air is drawn through the inlet channel 930 (andaround a cross-bar feature thereof) into the cartridge 900 of thedepicted implementation, the pressure sensor may detect a draw bysensing a pressure drop in the cartridge 900. When a draw is detected bythe pressure sensor, the control component directs current through theheating member 918 in order to heat the heating member 918. As theheating member 918 heats, at least a portion of the liquid compositioncontained in the liquid transport element 916 is vaporized in thevaporization chamber 932. Accordingly, aerosol produced in thevaporization chamber 932 may then directed to the user. In particular,as the air enters the cartridge 900 via the air inlet channel 930, theair travels through the vaporization chamber 932 where it impinges onthe heating member 918 substantially perpendicularly thereto and mixeswith the vaporized liquid composition to become the aerosol. Due to thegeometry of the vaporization chamber 932, the bottom cap 926, and/or thebase member 914, the aerosol is split into two separate paths thatextend through the inside of the bottom cap 926, around the heaterconnectors 920A, 920B, and then through the aerosol flow tubes 933A,933B that are defined on opposite sides of the reservoir cavity 928 ofthe tank 910. As shown in the figures, the two aerosol paths converge atthe proximal end of the tank 910 and below the upper aerosol channelinsert 906. The recombined aerosol then flows through the upper aerosolchannel insert 906 and out of the exit portal 915 of the mouthpiece 900,to the user.

Although in some implementations a cartridge and a control device may beprovided together as a complete aerosol delivery device generally, thesecomponents may be provided separately. For example, the presentdisclosure also encompasses a disposable unit for use with a reusableunit. In specific implementations, such a disposable unit (which may bea cartridge as illustrated in the appended figures) can be configured toengage a reusable unit (which may be a control device as illustrated inthe appended figures). In still other configurations, a cartridge maycomprise a reusable unit and a control device may comprise a disposableunit.

Although some figures described herein illustrate a cartridge and acontrol device in a working relationship, it is understood that thecartridge and the control device may exist as individual components.Accordingly, any discussion otherwise provided herein in relation to thecomponents in combination also should be understood as applying to thecontrol device and the cartridge as individual and separate components.

In another aspect, the present disclosure may be directed to kits thatprovide a variety of components as described herein. For example, a kitmay comprise a control device with one or more cartridges. A kit mayfurther comprise a control device with one or more charging components.A kit may further comprise a control device with one or more batteries.A kit may further comprise a control device with one or more cartridgesand one or more charging components and/or one or more batteries. Infurther implementations, a kit may comprise a plurality of cartridges. Akit may further comprise a plurality of cartridges and one or morebatteries and/or one or more charging components. In the aboveimplementations, the cartridges or the control devices may be providedwith a heating member inclusive thereto. The inventive kits may furtherinclude a case (or other packaging, carrying, or storage component) thataccommodates one or more of the further kit components. The case couldbe a reusable hard or soft container. Further, the case could be simplya box or other packaging structure.

Many modifications and other embodiments of the disclosure will come tomind to one skilled in the art to which this disclosure pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that thedisclosure is not to be limited to the specific embodiments disclosedherein and that modifications and other embodiments are intended to beincluded within the scope of the appended claims. Although specificterms are employed herein, they are used in a generic and descriptivesense only and not for purposes of limitation.

1. An aerosol delivery device comprising: a control device that includesan outer housing defining an outer wall and having a proximal end and adistal end, the proximal end of the control device defining a receivingchamber, the control device further including a power source and acontrol component; and a cartridge that includes a mouthpiece, a tank,and a heating assembly, the mouthpiece having a proximal end and adistal end, the proximal end of the mouthpiece having an exit portaldefined therethrough, the tank being configured to contain a liquidcomposition, wherein the cartridge is configured to be removably coupledwith the receiving chamber of the control device, wherein the heatingassembly defines a vaporization chamber and is configured to heat theliquid composition to generate an aerosol, wherein an inlet airflow isdefined by a gap between the cartridge and the control device, whereinthe gap originates at an interface between an outer peripheral surfaceof the mouthpiece and the control device, wherein the gap is establishedby a plurality of protuberances located on the control device, andwherein the plurality of protuberances comprises a plurality of raisedelongate bosses located on an upper frame of the control device.
 2. Theaerosol delivery device of claim 1, wherein the interface is locatedproximate an outer peripheral surface of the mouthpiece and a top edgeof the outer wall of the housing.
 3. The aerosol delivery device ofclaim 1, wherein the cartridge further includes a bottom cap, andwherein the inlet channel is located in the bottom cap.
 4. The aerosoldelivery device of claim 3, wherein the inlet airflow enters thecartridge through a single inlet channel located in an approximatecenter of a bottom surface of the bottom cap.
 5. The aerosol deliverydevice of claim 3, wherein the inlet channel located in the bottom caphas a nozzle-like shape.
 6. The aerosol delivery device of claim 3,wherein the gap between the cartridge and the control device isestablished between the outer housing and upper frame of the controldevice and the mouthpiece, tank, and bottom cap of the cartridge.
 7. Theaerosol delivery device of claim 1, wherein the heating assemblycomprises a flat heating member and a liquid transport element, andwherein the flat heating member and the liquid transport element areinstalled in a curved orientation.
 8. The aerosol delivery device ofclaim 3, wherein the vaporization chamber of the cartridge is defined bythe bottom cap and heating assembly.
 9. The aerosol delivery device ofclaim 1, wherein the tank further defines a reservoir cavity configuredto hold the liquid composition.
 10. The aerosol delivery device of claim1, wherein an aerosol path is defined through an upper aerosol channelinsert located between the tank and the exit portal of the mouthpiece.11. The aerosol delivery device of claim 1, wherein the distal end ofthe bottom cap of the cartridge includes a pair of inserts comprising aferromagnetic metal material.
 12. The aerosol delivery device of claim11, wherein an upper frame of the control device includes a pair ofmagnets configured to substantially align with the pair of metal insertsof the cartridge.
 13. The aerosol delivery device of claim 1, whereinthe control device includes a pressure sensor, and wherein the cartridgeand the control device include a pressure path configured to signal anegative pressure to the pressure sensor.
 14. The aerosol deliverydevice of claim 1, wherein an aerosol path originates at thevaporization chamber and is defined through the tank and the exit portalof the mouthpiece.
 15. The aerosol delivery device of claim 1, whereininlet air entering the vaporization chamber impinges on the heatingmember substantially perpendicularly thereto and spreads outsubstantially horizontally.